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Supplier Evaluation / QVR Assessment Workbook Index l l l l l l l l l l l Special Processes: AIAG CQI-9 Heat Treat System Assessment CQI-11 Plating System Assessment CQI-12 Coating System Assessment l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l CQI-15 Welding System Assessment CQI-17 Soldering System Assessment l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l Document Change Summary Instructions QVR / Supplier Evaluation Scoring QVR Process Map Cover (sheet) Supplier Evaluation Summary Quality Delivery Support & Technology Cost Print Review CQI-9 Instructions for Cover Shee CQI-11 Instructions for Cover CQI-12 Cover Sheet Instrts. CQI-9 Cover Sheet CQI-11 Cover Sheet CQI-12 Cover Sheet CQI-9 Elements, Sec. 1-3 CQI-11 Sections 1 & 2 General CQI-12 Section 1 & 2 General CQI-9 Job Audit, Sec. 4 CQI-11 Sect. 3 ZN-ZN Alys. Eq. CQI-12 Job Audit CQI-9 Assessor's Qual. Reqs.. CQI-11 Section 4-DECO Equip. CQI-12 Assessor's Quals. CQI-9 Process Table A CQI-11 Section 5 Job Audit CQI-12 Process Table A CQI-9 Process Table B CQI-11 Assessor's Quals. CQI-12 Process Table B CQI-9 Process Table C CQI-11 Process Table A CQI-12 Process Table C CQI-9 Process Table D CQI-11 Process Table B CQI-12 Process Table D CQI-9 Process Table E CQI-11 Process Table C CQI-12 Process Table E CQI-11 Process Table D CQI-12 Process Table F CQI-11 Process Table E CQI-12 Process Table G CQI-11 Process Table F CQI-12 Process Table H CQI-12 Process Table I CQI-12 Process Table J CQI-15 Cover Sheet Instrts CQI-17 Cover Sheet Instrts. CQI-15 Cover Sheet CQI-17 Cover Sheet CQI-15 Elements Section 1 - 5 CQI-17Sect. 1&2 - Gen. Overview CQI-15Job Audit Section 6 Proc. CQI-17 Section 3 - Equipment CQI-15 Arc Welding Table A CQI-17Section 4 - Job Audit CQI-15 Resist.Welding Table B CQI-17Proc. Tab. A Paste Print. CQI-15 Laser Welding Table C CQI-17 Process Table B Insp. CQI-15Solid State Weld. Table D CQI-17Proc. Tab. C Surface Mnt CQI-17 Proc. Table D Reflow CQI-17 Proc. Table E Glue Disp. CQI-17 Proc. Table F Flux CAI-17 Proc. Table G Pre-Heat CQI-17 Proc.Table H Wave CQI-17 Proc. Table I Fountain CQI-17Proc. Tab.J Dip Soldering CQI-17Proc Tab. K Select. Sold. CQI-17Tab. L Auto Iron Solding CQI-17Tab. M Man.l Iron Solder CQI-17Tab. N Laser & Soft Beam CQI-17 Tab. O Induction CQI-17Tab. P Conform. Coat&Tst CQI-17 Tab. Q PCB Seperation CQI-17Tab. R In-circuit Testing CQI-17 Tab. S Re-work

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Page 1: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation / QVR AssessmentWorkbook Index

l

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Special Processes: AIAG CQI-9 Heat Treat System Assessment CQI-11 Plating System Assessment CQI-12 Coating System Assessment

l l ll l ll l ll l ll l ll l ll l ll l ll l ll l l

l ll ll l

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CQI-15 Welding System Assessment CQI-17 Soldering System Assessment

l ll ll ll ll ll ll ll l

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Document Change Summary

Instructions

QVR / Supplier Evaluation Scoring

QVR Process Map

Cover (sheet)

Supplier Evaluation Summary

Quality

Delivery

Support & Technology

Cost

Print Review

CQI-9 Instructions for Cover Sheet CQI-11 Instructions for Cover CQI-12 Cover Sheet Instrts.

CQI-9 Cover Sheet CQI-11 Cover Sheet CQI-12 Cover SheetCQI-9 Elements, Sec. 1-3 CQI-11 Sections 1 & 2 General CQI-12 Section 1 & 2 GeneralCQI-9 Job Audit, Sec. 4 CQI-11 Sect. 3 ZN-ZN Alys. Eq. CQI-12 Job AuditCQI-9 Assessor's Qual. Reqs.. CQI-11 Section 4-DECO Equip. CQI-12 Assessor's Quals.CQI-9 Process Table A CQI-11 Section 5 Job Audit CQI-12 Process Table ACQI-9 Process Table B CQI-11 Assessor's Quals. CQI-12 Process Table BCQI-9 Process Table C CQI-11 Process Table A CQI-12 Process Table CCQI-9 Process Table D CQI-11 Process Table B CQI-12 Process Table DCQI-9 Process Table E CQI-11 Process Table C CQI-12 Process Table E

CQI-11 Process Table D CQI-12 Process Table FCQI-11 Process Table E CQI-12 Process Table GCQI-11 Process Table F CQI-12 Process Table H

CQI-12 Process Table ICQI-12 Process Table J

CQI-15 Cover Sheet Instrts CQI-17 Cover Sheet Instrts.CQI-15 Cover Sheet CQI-17 Cover SheetCQI-15 Elements Section 1 - 5 CQI-17Sect. 1&2 - Gen. OverviewCQI-15Job Audit Section 6 Proc. CQI-17 Section 3 - EquipmentCQI-15 Arc Welding Table A CQI-17Section 4 - Job AuditCQI-15 Resist.Welding Table B CQI-17Proc. Tab. A Paste Print.CQI-15 Laser Welding Table C CQI-17 Process Table B Insp.CQI-15Solid State Weld. Table D CQI-17Proc. Tab. C Surface Mnt

CQI-17 Proc. Table D ReflowCQI-17 Proc. Table E Glue Disp.CQI-17 Proc. Table F FluxCAI-17 Proc. Table G Pre-HeatCQI-17 Proc.Table H WaveCQI-17 Proc. Table I FountainCQI-17Proc. Tab.J Dip SolderingCQI-17Proc Tab. K Select. Sold.CQI-17Tab. L Auto Iron SoldingCQI-17Tab. M Man.l Iron Solder CQI-17Tab. N Laser & Soft Beam CQI-17 Tab. O Induction CQI-17Tab. P Conform. Coat&Tst CQI-17 Tab. Q PCB SeperationCQI-17Tab. R In-circuit TestingCQI-17 Tab. S Re-work

Page 2: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation (QVR) Change Summary (Rev. 6.0)1 Changed to Input-Process-Output (IPO) type format. Provided additional clarity to a couple of steps of the process.

1 Entire Supplier Evaluation is segregated into 4 key critical areas: Quality, Delivery, Support & Technology, and Cost .2 Counter on the Supplier Evaluation Score Summary page that displays total non-conformances by severity: either Major or Minor.

ANY element scored less than "7" will FAIL the entire audit. Additionally, a collective (total) score below 70%will also Fail the audit.

3 There are an areas findings sheet for each section. Any line item question that scores below 70% will automatically be displayed onthese findings sheets.

Deleted by Revision 5 dated July 15, 2010.4 A button has been added to take you directly to the AIAG Special Processes worksheets. By clicking 'YES" on the "COVER PAGE" you

will be immediately forwarded to the desired Special Processes Worksheet. If your facility doesn't handle any "SPECIAL PROCESSES" thenyou can depress the "NO" button on the "COVER PAGE" you will be asked to delete the corresponding worksheets, as they will not be required. This also reduces the size of the Supplier Evaluation / QVR Worksheet.

5 Have added the ability to answer "YES" or "NO" to each of the questions. If you answer "YES", the ranking defaults to "7" in the score; if youanswer "NO", the ranking defaults to "6". This allows you to answer a specific question without influencing the rest of the sections.NOTE: If the supplier has not satisfied any of the audit question, please label as "ZERO" (0), versus "NO".

6 You may also type in N/A for those areas that do not apply to this supplier. Notice that the "TOTAL POINTS POSSIBLE" will not change, soas to not penalize the supplier.

7 A supplier should receive a score of 7 if they meet the minimum requirements of a question. However if the supplier excels in an area, you mayreward them with the score of 8, 9, or 10. Any score over 7 will not increase the points possible.NOTE: Bonus points cannot improve any section over 100%.

a. Cover page altered to reflect areas of non-conformances (Quality, Delivery, Support & Technology, and Cost). b. Areas highlighted in "YELLOW" on the cover page and audit reports are the only cells that you may key information into.

Exceptions are in areas noted that may be overwritten as required. Example is 3d below.c. Have added area to show Corporate Addresses and phone numbers. The corporate area will autopopulate when you fill in the 'Manufacturing

Site' information. If the addresses are different, you still have the ability to overwrite the corresponding cells as needed.d. Bottom left hand corner displays whether or not a follow up audit will be required. This area is autopopulated, however may

be overwritten as needed.

a. Any finding with a ranking of less than 7 equates to a FAILED Supplier Evaluation / QVR Assessment.b. Supplier Evaluation totals below 70% equals a FAILED Supplier Evaluation / QVR Assessment.c. Any section / critical area as described above that falls below 70% equals a Failed Supplier Evaluation/QVR Assessment.

Revised to clarify language and responsibility (Process Map), and add Enviromental elements back in (omitted with Rel. 1.2)

Revised to add requirement for 'All applicable issues identified…" to be resolved (closed) PRIOR to Sourcing on 'Instructions' and 'QVR Scoring Key' worksheets.

A. PROCESS MAP:

B. SUPPLIER ASSESSMENT WORKSHEET

C. COVER PAGE:

D. PARAMETERS FOR WORKSHEET:

Page 3: Supplier Evaluation (QVR)Rev6 0112

Remy Inc.This document has been reviewed and approved by authorized personnel.

Approval date and name are recorded electronically in the document control system. The electronic version is the only controlled copy.

Rev. Level 3.5RCP-740

Supplier Evaluation (QVR) Overview

Purpose:

Application:

Instructions:

A general overview of the process is illustrated on the next worksheet of this file; reference

Note: For Remy internal use, refer to RCP-741 QVR Survey Letter.

Process Owner:Supplier Quality Department

To evaluate a potential supplier's process and procedures for effectiveness and capability for maintaining a high level of quality of potential purchased components.

The acronym 'QVR' stands "Quality, Value, Responsiveness", and is frequency used within Remy to be synonymous with a 'Supplier Evaluation' or 'Potential Supplier Assessment'.

The potential supplier will be given a rating from the Remy Supplier Quality Engineer upon completion of the assessment.

The Supplier Evaluation may be applicable whenever the project requires new suppliers and / or new parts.

The Program Manager, Purchasing Commodity Manager, or Supplier Quality Manager shall determine applicability for the specific supplier or component.

Prior to an on-site review, the responsible Remy Commodity Manager shall request the potential supplier to complete a Supplier Self-Assessment survey (Appendix C), located on the Remy Supplier web-page (http://www.remyinc.com/suppliers_manual.asp).

Upon receipt of the completed survey, Remy key-stakeholders (Commodity Mgr., Supplier Quality, Program Mgr.) will review the information provided and determine whether to proceed with an on-site evaluation. If so, the supplier will be contacted by Remy to coordinate an on-site verification of the supplier's capabilities.

The Cover page and QVR Survey are to be completed by Supplier Quality Engineer (or delegate). The cover summarizes the results of the QVR process audit for the specific supplier and part on the given date. The Survey provides the detailed assessment criteria for rating.

NOTE: ALL applicable issues identified (i.e. scores <7) MUST be resolved prior to Sourcing.

The Print Review Process may be utilized, at the discretion of the Supplier Quality Engineer and PDRE, when part prints (part numbers) for a given potential supplier are known at the time of the on-site assessment. This process may also be utilized at other times during the development process.

The results of the QVR Review will be maintained by the Supplier Quality Department (within the Remy PPAP Tracking System application). A non-controlled copy of the cover page may be filed in the program folder to provide program documentation.

QVR Process Map

Page 4: Supplier Evaluation (QVR)Rev6 0112
Page 5: Supplier Evaluation (QVR)Rev6 0112

SUPPLIER EVALUATION SCORING GUIDELINES Score

0

1

2

3

4

Implementation has progressed (60-80% complete) and there is preliminary evidence of relevant results. 5

6

7

8

9

10

Supplier is not familiar with the requirements of the element and has no relevant source documentation (flow charts, forecasts, plans, procedures, strategies, etc.) in this area.

Supplier is familiar with the requirements of the element, but there is no evidence of source documentation, planning, or implementation.

Supplier is familiar with the requirements of the element, and has preliminary source documentation with incomplete plans for implementation.

Source documentation is available. Implementation (with assigned responsibilities) has just started, (0-30% complete).

Source documentation is available and implementation is in progress (30-60% complete). Deficiencies have been identified but improvements are not quantifiable.

Implementation is nearly complete (80-95% complete) and documented evidence of implementation effectiveness exists.

Full implementation of source documentation for the requirement and complete confirmed evidence of implementation effectiveness. The supplier has met minimum requirements.

Analysis of results and on-going continuous improvement can be demonstrated in key areas linked to customer satisfaction.

Supplier has reached world class performance and is able to show growth beyond ISO-9000and TS16949 requirements and continuous improvement in all areas.

Supplier is "best-in-class" and is able to demonstrate significant innovation in new ways to show relevant results beyond the customer requirements. The supplier set the industry benchmark.

E13
0 = Supplier is not familiar with the requirements of the element and has no relevant source doucmentation (flow charts, forecasts, plans, procedures, strategies, etc.) in this area. 1 = Supplier is familiar with the requirements of the element, but there is no evidence of source documentation, planning, or implementation. 2 = Supplier is familiar with the element, and has preliminary source documentation with incomplete plans for implementation. 3 = Source documentation is available. Implementation (with assigned responsibilities) has just started, (0-30% complete. 4 = Source documentation is available and implementation is in progress (30-60% complete). Deficiencies have been identified but improvements are not quantifiable. 5 = Implementation has progressed (60-80% complete) and there is prelimary evidence of relevant results. 6 = Implementation is nearly complete (80-95% complete) and documented evidence of implementation effectiveness exists. 7 = Full implementation of source documentation for the requirement and complete confirmed evidence of implementation effectiveness. The supplier has met minimum requirements. 8 = Analysis of results and on-going continuous improvement can be demonstrated in key areas linked to customer satisfaction. 9 = Supplier has reached world class performance and is able to show growth beyond ISO-9000 and TS-16949 requirements and continuous improvements in all areas. 10 = Supplier is "Best In Class" and is able to demonstrate significant innovationin new ways to show relevant results beyond the customer requirements. The supplier set the industry benchmark.
Page 6: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

Supplier Evaluation Audit - Release 1.2 APPROVAL STATUS: NOT APPROVED Score: Fail

Individual Section Performance

FAIL 41%

FAIL 10%

Date Completed: FAIL 24%

FAIL 25%

Supplier Information

MANUFACTURING SITE CORPORATE SITE

Supplier's Name: Corporate Headquarters:

Street Address: Address:

City, State: City, State:

Zip code (or Mail Code): Zip code (or Mail Code):

Country: Country:

Telephone #: Corp. E-mail Address

Fax: SCAR Primary Contact Name

Commodity and/or Phone and Fax #

Service Provided: Email Address

SPECIAL PROCESSES (REF. AIAG GUIDELINES) Phone and Fax #

Email Address

Heat Treat Services Provided [YES / NO]

Plating Services Provided [YES / NO]

Coating Services Provided [YES / NO]

Welding Services Provided [YES / NO]

Soldering Services Provided [YES / NO]

Key personnel completing this survey:

SUPPLIER REPRESENTATIVES: REMY REPRESENTATIVES:

Name: Title Name: Title

Does this location have a quality system certification? ISO 9001:2000

Certificate Number Expiration Date: ISO/TS16949

Registrar

Certification Body Other (identify)

Follow-up Audit Required? Person responsible for audit corrective actions: Survey corrective action due date:

YES

The results of this audit have been explained to the supplier to the extent that expectations are understood.

Remy Representative Signature Supplier Representative Signature

QUALITY

DELIVERY

SUPPORT & TECH.

COST

SPECIAL PROCESSES

COMPLETE WORKSHEET AS

REQUIRED

Click Yes or No in Box Provided

PPAP Primary Contact Name

CQI-9 Heat Treat-SP1

CQI-11 Plating - SP2

CQI-12 Coating - SP3

CQI-15 Welding - SP4

CQI-17 Soldering - SP5

ISO14000

NOTE: ALL "open" issues identified MUST be resolved PRIOR to Sourcing.

YES

YES

NO

NO

NO

YES

YES

YES

NO

NO

O3
Will display 'FAIL' in lieu of value if <70% OR has a MAJOR finding.
P3
Will display 'FAIL' is <70% OR has a MAJOR finding.
K12
Input if different from Manufacturing Site:
J23
Input if different from SCAR Primary Contact
C47
YES or NO Note: Will default to YES if failed. May be overwritten IF not required
Page 7: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES RED MinorSums SDE COMMENTS SUPPLIER ACTIONS RESP DUE

Qu

alit

y

Q-1 Quality System Capability 30 M 0 FAIL 1 2Q-2 Internal Audit 50 M 0 FAIL 2 3

Q-3 30 M 0 FAIL 1 2Q-4 APQP 30 M 0 FAIL 1 2Q-5 PPAP 40 M 0 FAIL 2 2Q-6 Document Control System 30 M 0 FAIL 1 2Q-7 Training Records 40 M 0 FAIL 1 3Q-8 Final Inspection 60 M 0 FAIL 2 4Q-9 Process Control 60 M 0 FAIL 2 4

Q-10 Nonconforming Material Control 30 M 0 FAIL 2 1

Q-11 50 M 0 FAIL 2 3Q-12 Supplier Control 40 M 0 FAIL 2 2

0.00% Q-13 Control of Supplied Material 20 M 0 FAIL 1 1 ###

Del

iver

y

D-1 100 M 0 FAIL 2 80.00% D-2 Material ID and Traceability 30 M 0 FAIL 3 0 ###

S-1 30 0 FAIL 0 3

S-2 Technical Capability 110 M 0 FAIL 5 6

S-3 Housekeeping 40 0 FAIL 0 4

S-4 Facility Security- All Required 40 M 0 FAIL 4 0

0.00% S-5 Information systems 80 M 0 FAIL 8 4 ###

Co

st

C-1 Lean Manufacturing 50 0 FAIL 0 5C-2 Preventive Maintenance Program 40 M 0 FAIL 2 2

C-3 150 M 0 FAIL 5 100.00% C-4 Business Management Systems: Materials 70 0 FAIL 0 7 ###

All Section Totals 1250 M 0 FAIL 49 80 0

NOTE: Only areas in dull yellow are editable

Total Points Possible for a World Class

Supplier

M = Major

SCOREMajor Sums

Note: Score in accordance with

AIAG "Quality System

Assessment" manual unless

otherwise noted.

Corrective & Preventative action system

Control of Inspection, Measuring, and Test Equipment (IMTE)

Dock Storage, Material Handling, and Packaging

Su

pp

ort

&

Tec

hn

olo

gy Process/ Tool/ Die/ Jig/

Fixture/ Part Design Control

Business Management Systems:Production Capacity, Planning, and Scheduling

Cover PageCover Page

Index PageIndex Page

F2
Click on SCORE to see AIAG QSA Scoring Guidelines
G2
RED SCORE <7
Page 8: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE

Q-1 Quality System Capability 30 M 0 FAIL RED SCORE <7

1 10 M 0 REDIs the supplier certified to any Quality System?

1

2 10 0 RED 1

3 10 0 RED 1

Q-2 Internal Audit 50 M 0 FAIL RED SCORE <71 Is there a current Internal Audit schedule? 10 M 0 RED 12 Are audits conducted as scheduled? 10 M 0 RED 1

3 10 0 RED 1

4 10 0 RED 1

5 10 0 RED 1

Q-3 30 M 0 FAIL RED SCORE <7

1 10 M 0 RED 1

2 10 0 RED 1

3 10 0 1

Q-4 APQP 30 M 0 FAIL RED SCORE <71 Does the supplier have a formal / documented APQP process? 10 M 0 RED 1

2Does the supplier have a standard form to document APQP requirements?

10 0 RED 1

3 10 0 RED 1

Total Points Possible for a World Class

SupplierSCORE

Amt. Of Major

Findings

Amt. of Below 70%

Observations

Is the supplier TS-16949 Certified? If No do they have a plan to achieve TS-16949 Certification?

Is there access to e-mail and the World Wide Web provided for those individuals with Quality and Management responsibilities?

Is the key quality contact for the plant location accessible via telephone (either land line or cell phone) and Email?

Are there regular (at least monthly) standard work audits that are cascading and performed by leadership?

For any Internal Corrective Action (ICAR) is there a functional management review procedure in place.

Are corrective actions and follow-up carried out to verify that actions taken are effective?

Corrective & Preventative action system

Does the supplier's process require documentation of the non-conformance (7-Step or 8D), containment and inspection of affected material when a non-conformance is found either by the supplier or the customer?

Does the supplier have a corrective action system and use analysis tools such as A3 Story-Board, 8D, 7D, 7 step, 5 phase, etc.?

Has the supplier been placed in a controlled shipment or New business hold status with the last 6 months? Answer "Yes Or No"

Is there evidence that a system exists to support design, procure, manufacture, develop, and implement new production tooling (i.e. Gantt charts, supplier selection, tool validation/runoff, PPAP/runoff at manufacturing location)?

Cover PageCover Page

Index PageIndex Page

H1
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
C3
SCORE: 10 (+3 bonus) = Sets the standard, best practice, global benchmark [- NO Majors, NO MInors, nor No Observations. The best of the best.] 9 (+2 bonus) = Uses proactively AND has achieved "World Class" performance levels [If no Major nor Minor findings in last two audits.] 8 (+1 bonus) = Uses proactively for continuous improvement 7 (+0 bonus) =Meets requirements, not only in procedure but in performance [If only 5-6 minor findings, then supplier meets the minumum requirements for this section.] 6 (-1 penalty) = if 1 major finding. 4 - if 2 or more major findings. 2 - if major findings with no corrective action accepted to date. 1 - if decertification has been recommended by registrar. 0 = No aspects of requirement in place (non-existent)
E3
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E4
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
H4
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E5
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
H5
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E7
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E8
If score is above (bonus) or below (penalty) Seven [7], describe reason for score..
E9
If score is above (bonus) or below (penalty) Seven [7], describe reason for score
E10
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E11
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E13
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E14
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E15
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E17
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E18
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E19
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
Page 9: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE

Q-5 PPAP 40 M 0 FAIL RED SCORE <7

1 10 M 0 RED 1

2 10 M 0 RED 1

3The supplier shall have the AIAG electronic version of PPAP documentation

10 0 RED 1

4 10 M 0 RED 1

Q-6 Document Control System 30 M 0 FAIL RED SCORE <7

1 10 0 RED 1

2 10 M 0 RED 1

3 10 0 RED 1

Q-7 Training Records 40 M 0 FAIL RED SCORE <7

1 10 0 RED 1

2 10 0 RED 1

3 10 0 RED 1

4 10 M 0 RED 1

Q-8 Final Inspection 60 M 0 FAIL RED SCORE <7

1 10 0 RED 1

2 10 0 RED 1

3 10 0 RED 1

4 10 M 0 RED 1

5 10 0 RED 1

6 10 M 0 RED 1

Points Possible SCORE Sum of

MajorsSum of Section

NC

Are appropriate procedures in place for preparation of PPAP documentation in accordance with AIAG guidelines?

Are there approved customer PPAP's on file that correlate to the current revision of prints being used for production?

The Supplier must have an IMDS account and at least 1 trained person. Answer YES or NO.

Is there a master list(s) of all controlled documents (or acceptable alternative) readily available which indicates document approval status and revision?

Are all changes (revisions) identified on each document and do these revision notes indicate the purpose/reason for the change? (includes control plans, process flow diagrams, and PFMEA's).

Is there a system in place to track when changes are implemented relative to production parts?

Are records available to show that production operators have been trained in their operations?

Are employee training needs documented and are records of completed training maintained?

Are there specific training records documenting operator training in processes necessary for the commodity being considered?

Is there objective evidence that all personnel are trained using the company procedure for emergency, unplanned shutdowns and power outages (including quarantine and inspection of materials made before, during and after the emergency)?

Does the supplier carry out final inspection and testing in accordance with the quality plan (Control Plan) and/or documented procedures?

Does the supplier hold product until the required inspections and tests have been completed or necessary reports have been received and verified, except for release under positive recall?

Does the supplier conduct scheduled audits of the packaged final product to verify conformance to all specified requirements.

Does the supplier maintain records which provide evidence that the product has been inspected and/or tested, clearly showing whether the product has passed or failed inspection based on the defined acceptance criteria, and identifying the authority responsible for the product release?

Are first piece inspected parts retained until final data is complete to enable traceability to raw data?

Are set-up and partially finished first piece sample inspected parts scrapped after final data is complete? If those parts are finished and not scrapped is there a control system in place to assure they are properly finished to specification. These parts must be identified, contained and separately inspected and released.

E22
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E23
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E24
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E25
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E27
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E28
ThomasD:If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E29
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E31
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E32
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E33
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E34
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E36
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E37
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E38
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E39
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E40
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E41
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
Page 10: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE

Q-9 Process Control 60 M 0 FAIL RED SCORE <7

1 10 M 0 RED 1

2 10 M 0 RED 1

3 10 0 RED 1

4 Is inspection data from the process recorded? Are records available? 10 0 RED 1

5 10 0 RED 1

6 10 0 RED 1

Q-10 Nonconforming Material Control 30 M 0 FAIL RED SCORE <7

1 10 M 0 RED 1

2 10 M 0 RED 1

3 10 0 RED 1

Q-11 50 M 0 FAIL RED SCORE <7

1 10 0 RED 1

2 10 M 0 RED 1

3 10 M 0 RED 1

4 10 0 RED 1

5 10 0 RED 1

Total Points Possible for a World Class

SupplierSCORE Sum of

MajorsSum of Section

NC

Are individual operations specified by detailed work and inspection instructions that are readily available? (I.e. drawings showing process steps, standardized format, photos of actual process steps)

Do the supplier's procedures require approval of processes and equipment after set-ups, tool changes, prior to actual use? Are there specified criteria for first piece approval?

Are workmanship standards defined by written specifications, photographs, and / or labeled boundary samples that are readily available to the operator?

Is SPC used to track variability in the process for controlling process parameters? Are corrective actions recorded for out of control conditions?

Does the supplier have a document that explains in detail the type of machines and sizes for each operation (s) that will be used for the commodity being requested? Is it readily available?

Do the supplier's procedures require isolation, containment, and visual identification of nonconforming material sufficient to prevent unauthorized use and/or shipment?

Are the non-conforming materials isolated and identified per the above procedure so that they are not used or shipped?

Does the supplier have a documented procedure for immediate customer notification in the event that it is suspected that nonconforming material may have been shipped?

Control of Inspection, Measuring, and Test Equipment (IMTE)

Is special or final test equipment verified after set-up, maintenance, and changeover?

Is the calibration of each piece of IMTE verified at prescribed intervals, against certified equipment traceable to recognized international or national standards?

Are IMTE calibration operations carried out in an appropriately controlled environment? Are there records to verify this?

Are appropriate records kept of IMTE calibration that include the type of equipment, identification, location, frequency of calibration, verification method, acceptance method, and any necessary corrective action?

Does the calibration system include employee-owned equipment used for product inspection?

G42
RED SCORE <7
E44
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E45
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E46
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E47
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E48
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E51
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E52
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E53
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E55
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E56
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E57
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E58
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E59
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
Page 11: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE

Q-12 Supplier Control 40 M 0 FAIL RED SCORE <7

1 10 M 0 RED 1

2 10 0 RED 1

3 10 0 RED 1

4 10 M 0 RED 1

Q-13 Control of Supplied Material 20 M 0 FAIL RED SCORE <7

1 10 M 0 RED 1

2 10 0 RED 1

Total Points Possible for a World Class

SupplierSCORE Sum of

MajorsSum of Section

NC

Are suppliers selected and evaluated based on their ability to meet quality system and quality assurance requirements?

Are records maintained of supplier performance to quality system, delivery, and product quality requirements, including appropriate corrective actions?

Are on-site assessments of supplier capabilities performed and documented as appropriate? Note; commercially available or trade name items are exempt.

Are special processes such as heat treat, plating, or coating subcontracted? (separate QVR must be used if sub-contracted) Has the HT survey been performed and Passed? HT, Plating and coating suppliers must have ISO14000 or Use Environmental Self Survey and approval by Remy Corp EH&S.

Does the supplier's receiving quality system use at least one of the following methods to qualify product prior to use: (1) evaluation of supplier statistical data, (2) receiving inspection and/or testing, (3) combination of supplier quality system assessments and supplier quality performance history, (4) third party product evaluation/testing?

Are material storage areas clean, well organized, and sufficiently maintained to (1) preserve traceability information, (2) prevent damage, and (3) prevent contamination with undocumented or uninspected goods?

E62
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E63
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E64
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E65
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E67
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E68
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
Page 12: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE

Q-1 Quality System Capability 30 M 0 FAIL RED SCORE <7 1 2Q-2 Internal Audit 50 M 0 FAIL RED SCORE <7 2 3

Q-3 30 M 0 FAIL RED SCORE <7 1 2

Q-4 APQP 30 M 0 FAIL RED SCORE <7 1 2Q-5 PPAP 40 M 0 FAIL RED SCORE <7 2 2Q-6 Document Control System 30 M 0 FAIL 1 2Q-7 Training Records 40 M 0 FAIL RED SCORE <7 1 3Q-8 Final Inspection 60 M 0 FAIL RED SCORE <7 2 4Q-9 Process Control 60 M 0 FAIL RED SCORE <7 2 4

Q-10 Nonconforming Material Control 30 M 0 FAIL RED SCORE <7 2 1

Q-11 50 M 0 FAIL RED SCORE <7 2 3

Q-12 Supplier Control 40 M 0 FAIL RED SCORE <7 2 2Q-13 Control of Supplied Material 20 M 0 FAIL RED SCORE <7 1 1

Quality Section Total 510 M 0 FAIL 0.00% 20 31*Only areas in dull yellow are editable*

Total Points Possible for a World Class

SupplierSCORE Sum of

MajorsSum of Section

NC

Corrective & Preventative action system

Control of Inspection, Measuring, and Test Equipment (IMTE)

Page 13: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Page 14: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Page 15: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Page 16: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Page 17: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

*Only areas in dull yellow are editable*

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Page 18: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS RESP DUE

D-1 100 M 0 FAIL

1 10 0 RED

2 10 0 RED

3 10 0 RED

4 10 M 0 RED

5 10 0 RED

6 10 0 RED

7 10 0 RED

8 Is the dock clean and orderly? 10 0 RED

9 10 0 RED

10 10 M 0 RED

D-2 Material ID and Traceability 30 M 0 FAIL

1 10 M 0 RED

2 10 M 0 RED

3 10 M 0 RED

Total Points

Possible for a World

Class Supplier

SCORE SUPPLIER ACTIONS

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Dock Storage, Material Handling, and Packaging

Is there a material handling and storage system in use that adequately preserves part quality and integrity during the production process (i.e. correct size and weight containers, adequate for projected lot sizes and pulls, protection against elements (rust, corrosion, physical damage, contamination, and equipment available to safely move containers from operation to operation.)?

Does this system capture net and gross weight of individual and packaged components?

Evaluate the inventory management system and it's ability to optimize inventory turns, assure stock rotation and minimize inventory levels?

Evaluate the system which assures material that has passed final inspection and is packaged for shipment, is labeled and identified correctly?

Does the supplier control the packing, packaging and marking processes so as to ensure product conformance to specifications?

Are materials shipped in conformance with the customer requirements adhering to up-to-date customer specified transportation mode and routings?

Does the supplier have a computerized system for receiving customer planning information and ship schedules and Advanced Shipping Notifications (ASN'S), unless waived by the customer?

Are there adequate storage areas for WIP and finished goods? (i.e. adequate for projected lot sizes and pulls, protection against elements, equipment necessary for safe moves of product)

Is there a system in place that allows for UPS, FED X, or DHL orders to be received or shipped as necessary.

Does identification of purchased materials and their records maintain traceability to material certifications and test reports?

Do records show that lot identity and disposition are maintained throughout the supplier's manufacturing and delivery process to assure lot integrity and traceability to materials used and processes performed?

Do process records adequately reflect process and inspection status throughout the system, including storage and in-process holding areas?

Cover PageCover Page

Index PageIndex Page

E3
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E4
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E5
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E6
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E7
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E8
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E9
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E10
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E11
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E12
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E14
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E15
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E16
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
Page 19: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS RESP DUE

D-1 100 M 0 FAIL

D-2 Material ID and Traceability 30 M 0 FAILDelivery Section Total 130 M 0 FAIL 0

*Only areas in dull yellow are editable*

Total Points

Possible for a World

Class Supplier

SCORE SUPPLIER ACTIONS

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Dock Storage, Material Handling, and Packaging

Page 20: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS RESP DUE

S-1 30 0 FAIL

1 10 0 RED

2 10 0 RED

3 10 0 RED

S-2 Technical Capability 110 M 0 FAIL

1 10 M 0 RED

2 10 0 RED

3 10 M 0 RED

4 10 0 RED

5 10 0 RED`

6 10 M 0 RED

7 10 0 RED

8 10 0 RED

9 10 M 0 RED

10 10 M 0 RED

11 10 0 RED

S-3 Housekeeping 40 0 FAIL

1 10 0 RED

2 10 0 RED

3 10 0 RED

4Are all Indirect materials clearly identified and placed in areas designated.

10 0 RED

Total Points

Possible for a

World Class

Supplier

SCORE SUPPLIER ACTIONS

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Process/ Tool/ Die/ Jig/ Fixture/ Part Design Control

Are records available of formal documented design reviews by the appropriate functions conducted at appropriate stages of design per the design plan?

Are design changes identified, documented, reviewed and approved by authorized personnel before implementation?

Does the supplier have documented procedures for controlling customer documents, i.e., drawings and specifications?

Does the supplier have relevant experience with the commodity or service being considered?

Do the supplier's current processes and equipment require improvement or development to manufacture the product or perform the service being considered?

For Special characteristics, does the supplier perform capability studies on new and ongoing processes? There must be evidence that on-going processes are capable.

Does the supplier have access to product or tooling development in-house or with a parent company?

Are all required inspection devices on site to inspect Remy parts to validate engineering specifications?

Are there qualified manufacturing engineering and technical resources available to support the commodity being considered?

Does the supplier have resources available for the support of tool and gage design and fabrication? (ex. Computer aided design system, tool room, EDM capabilities, as necessary.)

Is there a method to capture Tooling cost, tool life, and tool description for each operation. Is it available for review?

Are there specific Quality Assurance Engineering and other technical resources available necessary to support the commodity being considered?

Is there evidence that a system exists to design, develop, and implement new production quality plans and systems for the commodity being considered? (i.e. Gantt or MS Project, preliminary process flow, preliminary PFMEA, preliminary Control Plan, capability studies, gage R&R, PPAP, and gaging instructions.)

Does the supplier possess the applicable heat treat and/or plating specifications and necessary inspection equipment?

Is the supplier's plant layout clean, efficient, organized, and well lighted with demonstrated evidence of "good housekeeping" being practices throughout the manufacturing process?

Lighting should be sufficient to carry out visual work and recording at or near the activity. IS it?

Operations should be organized to facilitate good material flow and minimize the potential for handling damage to occur.

Cover PageCover Page

Index PageIndex Page

E1
Click on SCORE to see AIAG QSA Scoring Guidelines
G1
RED SCORE <7
E3
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E4
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E5
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E7
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E8
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E9
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E10
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E11
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E12
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E13
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E14
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E15
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E16
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E17
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E19
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E20
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E21
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E22
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
Page 21: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M=Major RED SDE COMMENTS RESP DUE

S-4 Facility Security- All Required 40 M 0 FAIL

1 10 M 0 RED

2 10 M 0 RED

3 10 M 0 RED

4 10 M 0 RED

S-5 Information systems 80 M 0 FAIL

1 10 M 0 RED

2 10 M 0 RED

3 10 M 0 RED

4 Does the supplier have a disaster recovery plan? 10 M 0 RED

5 10 0 RED

6 10 0 RED

7 10 0 RED

8 10 0 RED

End

Total Points

Possible for a

World Class

Supplier

SCORE SUPPLIER ACTIONS

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Are all external and internal doors, windows, gates, and fences protected with locking devices adequate to prevent unauthorized entry?

Is the physical security of international, domestic, high-value, and dangerous goods cargo assured by being properly marked, and segregated within the warehouse by use of a safe, caged, or otherwise fenced-in area?

Is unauthorized access to the shipping, loading dock and cargo areas prohibited? Controls must include the positive identification of all employees, visitors and vendors.

Are there measures in place requiring proper storage of empty and full containers to prevent unauthorized access?

Does the supplier have the capability to respond to Remy with a “Ship To” date based on the initial order over the Internet within 24 hours?

When the supplier receives the forecast, is there a system in place to measure performance against it?

Do you have a system that communicates your demand signals to your suppliers?

Do you have a network infrastructure/bandwidth system that exists to support manufacturing and business processes?

Are the following: Smoke Detection and Fire Suppression resident at this site?

How do you segregate customer specific data and information within your systems.

Does the supplier use any special security "firewall"/encryption solutions to securely communicate with your customers any sensitive information?

E25
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E26
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E27
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E28
ThomasD:If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E30
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E31
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E32
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E33
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E34
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E35
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E36
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E37
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
Page 22: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M=Major SCORE RED SDE COMMENTS RESP DUE

S-1 30 0 FAILS-2 Technical Capability 110 M 0 FAILS-3 Housekeeping 40 0 FAILS-4 Facility Security- All Required 40 M 0 FAILS-5 Information systems 80 M 0 FAIL

Support Section Total 300 M 0 FAIL 0.00% *Only areas in dull yellow are editable*

End

Total Points

Possible for a

World Class

Supplier

SUPPLIER ACTIONS

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Process/ Tool/ Die/ Jig/ Fixture/ Part Design Control

Page 23: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS RESP DUE

C-1 Lean Manufacturing 50 0 FAIL RED SCORE <7C.1.1 Is the factory layout designed to support Lean Manufacturing? 10 0 RED

C.1.2 10 0 RED

C.1.3 Is the supplier working in cells? 10 0 REDC.1.4 Is the supplier practicing one-piece flow concept? 10 0 REDC.1.5 Is the work in process on a pull system? 10 0 REDC-2 Preventive Maintenance Program 40 M 0 FAIL RED SCORE <7

C.2.1 10 M 0 RED

C.2.2 10 0 RED

C.2.3 Does the supplier monitor equipment uptime/downtime? 10 0 RED

C.2.4 10 M 0 RED

C-3 150 M 0 FAIL RED SCORE <7

C.3.1 10 0 RED

C.3.2 10 0 RED

C.3.3 10 M 0 RED

C.3.4 10 M 0 RED

C.3.5 10 M 0 RED

C.3.6 10 M 0 RED

C.3.7 10 0 RED

C.3.8 10 0 RED

C.3.9 10 0 RED

C.3.10 10 M 0 RED

C.3.11 10 0 RED

C.3.12 10 0 RED

C.3.13 10 0 RED

C.3.14 10 0 RED

C.3.15 10 0 RED

Total Points Possible for

a World Class

Supplier

SCORE SUPPLIER ACTIONS

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Is the supplier practicing lean concepts for product and process development?

Is there a schedule of planned maintenance on all machinery, tooling, and equipment in the process?

Are records available for all maintenance activities planned and unplanned? Root cause and corrective action should be included in unplanned maintenance records?

Is there a clearly defined and documented plan for emergencies, unplanned shutdowns and power failures? Plan must include responsibilities, evacuation procedure, re-start and quarantine/inspection of materials produced before, during and after the emergency/failure.

Business Management Systems:Production Capacity, Planning, and Scheduling

Can the supplier demonstrate that their production planning methodology is capable of satisfying customer demands- 100% on-time shipments.

Is there evidence of corrective action taken when delivery schedule compliance is less than 100% on-time?

Is the production forecast process automated or is it currently supported by a manual Forecast process?

Is this someone who reviews the forecast? Is there a process to approve the response prior to commitment to the customer.

Describe your daily production planning process and review. Is there a documented system available and is it being followed.

How do you track/ review / measure performance to schedule/ commit. Is this used as a planning tool?

What process safeguards exist to track product through-put and status? Is documented system being followed?

How do you support short term upside requests and what incremental capacity level is maintained? Is system being followed?

What long term capacity limitations exist for this site (Raw/Manufacture etc). Is there an contingency plan for production to be completed in the event of an emergency?

Is there a procedure to determine the quantity of equipment, size and physical plant layouts. to complete weekly production volumes without serious detriment to overall operations and part quality? Current capacity utilization is ~40%, based on a __hours, __shift, __ days per work week.

How and when are risks/misses communicated to your customer, mgmt? Is the system documented and followed?

Does the supplier have a system in place that determines if the operations will be completed in house or sub-let? Is it documented?

Does the supplier have a system (Documentation) in place that captures, labor rate per hour per operation, manning requirements at each operation, set up costs at each operation, and other fixed and variable costs associated with each operation? Is this readily available to review?

Does the supplier have a system in place that reviews all associated operations costs; (i.e.raw material, packing, packaging, scrap, and transportation) that displays that costs and goals are being met? Is this document available for review?

Does the supplier have a system that calculates expenses and profits associated with SG&A (Sales, General & Administration)

Cover PageCover Page

Index PageIndex Page

E1
Click on SCORE to see AIAG QSA Scoring Guidelines
G1
RED SCORE <7
E3
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E4
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E5
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E6
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E7
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E9
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E10
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E11
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E12
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E14
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E15
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E16
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E17
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E18
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E19
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E20
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E21
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E22
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E23
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E24
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E25
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E26
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E27
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E28
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
Page 24: Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010

REQUIREMENT CATEGORIES M=Major RED SDE COMMENTS RESP DUE

C-4 Business Management Systems: Materials 70 0 FAIL RED SCORE <7

C.4.1 10 0 RED

C.4.2 10 0 RED

C.4.3 Is there a procedure and process for an escalation path for part shortages? 10 0 RED

C.4.4 10 0 RED

C.4.5 10 0 RED

C.4.6 Is there a documented process to perform cycle counts? Is it used? 10 0 RED

C.4.7Is there a Corrective Action Process in place for inventory non-conformances

10 0 RED

REQUIREMENT CATEGORIES M=Major RED SDE COMMENTS RESP DUE

C-1 Lean Manufacturing 50 0 FAILC-2 Preventive Maintenance Program 40 M 0 FAIL RED SCORE <7

C-3 150 M 0 FAIL RED SCORE <7C-4 Business Management Systems: Materials 70 0 FAIL

Cost Section Total 310 M 0 FAIL 0.00%*Only areas in dull yellow are editable*

Total Points Possible for

a World Class

Supplier

SCORE SUPPLIER ACTIONS

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Does the company have strategic objectives for materials and supply chain management?

Is there a method to determine which items are purchased centrally and which from mfg. Site?

Does the supplier have a system that tracks the number of orders with on-time delivery (OTD) from their suppliers? What is the result during last 6 months?

Does the supplier have a system in place that confirms the product and quantities in their software, coorelates with the product quantities that are physically on the floor is correct?

Total Points Possible for

a World Class

Supplier

SUPPLIER ACTIONS

Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.

Business Management Systems:Production Capacity, Planning, and Scheduling

E31
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E32
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E33
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E34
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E35
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E36
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
E37
If score is above (bonus) or below (penalty) Seven [7], describe reason for score.
Page 25: Supplier Evaluation (QVR)Rev6 0112

REMY INTERNATIONAL, INC. Supplier QVR Source Evaluation Audit

Part Number

The proposed parts that the supplier will produce must be reviewed with representatives present from the following functional areas.

1 Is there consensus that ALL dimensions and features are manufacturable?Note Exceptions:

Yes2 Is there consensus that all dimensions are properly tolerance?

Note Exceptions:

Yes3 Is the part designed optimally for the process and material?

Note Exceptions:

Yes4 Is the part dimensioned properly to allow for proper gaging (correct datums and basic dimensions)?

Note Changes Required:

Yes5 Is gaging available to measure all features shown on the print?

Note Exceptions:

Yes6 Is there a clear understanding that all KPC items will require a CPK of 1.67 or greater?

Note Exceptions:

Yes7 Is GR&R known for gages that will be used for KPC’s? (must be less than or equal to 10%)

Note Exceptions and GR&R value:

Yes8 Does the supplier have access to the applied specifications (Paint, Materials, Plating, Heat Treatment Etc)

What do they need?:

Yes9 Have the DFMEA items for this part been reviewed with the supplier?

List Items:

Yes10 Does the Supplier have a preliminary process flow established? Is it acceptable to Remy?

Note Exceptions:

Yes

Part Print Review

•        Supplier’s Manufacturing Representative• Supplier’s Quality Engineering

    •     Remy Production Engineering        •  Remy Supplier Quality         • Supplier’s Raw Material and Sub-Suppliers

Cover PageCover Page Index PageIndex Page

Page 26: Supplier Evaluation (QVR)Rev6 0112

CQI-9 HEAT TREAT SYSTEM ASSESSMENTInstructions for completing the Cover Sheet

1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physicallocations in the same general area. If there is a separate management team (Quality Manager andMetallurgist) or different management system, then these locations shall be considered asseparate facilities.

2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.

3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.

4 Fax number: The fax number of the facility.

5 Number of Heat Treat Employees at this Facility: The number of employees, salaried and hourly, associated with the Heat Treat operation at this facility.

6 Captive Heat Treater (Y/N): Enter "Y" if this facility heat treats components for their own company. Enter"N" if the company does not Heat Treat any components for their own company.

7 Commercial Heat treater (Y/N): Enter "Y" if this facility Heat Treats components for companies other thantheir own company. Enter "N" if this facility does not Heat Treats any components for other companies.

8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.Example: May 3 -- 4, 2006.

9 Date of Previous Assessment: List the date of the previous CQI-9 Special Process: Heat TreatSystem Assessment of this facility.

10 Type(s) of Thermal Processings at this Facility: Place a checkmark to designate the thermal process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the Heat TreatSystem Assessment.

11 Current Quality Certification(s): the heat treater shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.

12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the heat treater shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 4, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.

13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the plater's organization.

14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).

15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.

16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.

17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.

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Page 27: Supplier Evaluation (QVR)Rev6 0112

Special Process: Heat Treat System Assessment

Facility Name:Address:

Phone Number: Type(s) of Thermal Processing at this Facility:Fax Number: Process Table A - Ferrous

CarburizingNumber of Heat Treat Employees at this Facility: Carbonitriding

Carbon CorrectionCaptive Heat Treater (Y/N): Neutral Hardening

Quench & TemperCommercial Heat Treater (Y/N): Austempering / Martempering

TemperingPrecipitation Hardening / Aging

Process Table B - FerrousNitriding (Gas)

Process Table C - AluminumAluminum Heat Treatment

Process Table D - FerrousInduction Heat Treating

Process Table E AnnealingNormalizingStress-Relieving

Current Quality Certification(s):

Date of Re-assessment (if necessary):

Personnel Contacted:Name: Title: Phone: Email:

0 00 00 00 0

Auditors/Assessors:Name: Company: Phone: Email:

000

Number of "Not Satisfactory" Findings:

Number of "Needs Immediate Action" Findings:

Number of "Fail" Findings in the Job Audit(s):

Date of Assessment:

Date of Previous Assessment:

Ferritic-Nitrocarburizing (Gas or Salt)

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Page 28: Supplier Evaluation (QVR)Rev6 0112

Special Process: Heat Treat System Assessment

Assessment

Question Requirements and Guidance Objective Evidence N/A Satisfactory

Section 1 - Management Responsibility & Quality Planning

1.1

1.2

1.3

1.4

Question Number

Not Satisfactory

Needs Immediate Action

Is there a dedicated and qualified heat treat person on-

site?

To ensure readily available expertise, there shall be a dedicated and qualified heat treat person on site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including metallurgical and heat treat knowledge. The qualifications shall include a minimum of 5 years experience in heat treat operations or a combination of a minimum of 5 years of formal metallurgical education and heat treat experience.

Does the heat treater perform advanced quality planning?

The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The heat treater shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.

Are heat treat FMEA's up to date and reflecting current

processing?

The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEA's are updated to reflect current part quality status.The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key heat treat process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.

Are heat treat process control plans up to date and reflecting

current processing?

The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls.The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key heat treat process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEA's. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables, Sections 3.0 and 4.0.

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Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page

1.5

1.6

1.7

1.8

Are all heat treat related and referenced specifications current and available? For example: SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler.

To ensure all customer requirements are both understood and satisfied, the organization shall have all related heat treat and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards / specifications and changes based on customer-required schedule. Timely review should be as soon as possible and shall not exceed two working weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks.

Is there a written process specification for all active

processes?

The heat treater shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, atmosphere or gas flow settings, belt speeds, quench agitation speeds, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control. All active processes should have a written process specification. These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.

Has a valid product capability study been performed initially and after process equipment has been relocated, or had a

major rebuild?

To demonstrate each process is capable of yielding acceptable product the organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, & after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all heat treat processes per furnace line defined in scope of work & in accordance with customer requirements. A furnace line may include a combination of equipment that is integrated in the performance of a heat treatment process, e.g., hardening, quenching, and tempering. Capability study techniques shall be appropriate for the heat treat product characteristics, e.g., tensile strength, case depth, hardness. Any specific customer requirements shall be met, in the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to followed in case capability indices fall outside customer requirements or established ranges.

Does the heat treater collect and analyze data over time,

and react to this data?

The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time.Methods of analysis shall include ongoing trend or historical data analysis of product or process parameters. The organization shall determine which parameters to include in such analysis.

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Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page

1.9

1.10

1.11

1.12

1.13

1.14

1.15

1.16

Is management reviewing the heat treat monitoring system

every 24 hours?

Management shall review the furnace monitoring systems at intervals not to exceed 24 hours. The heat treat monitoring system includes but is not limited to temperature strip charts, atmosphere strip charts, computer data logs, furnace and operator logs, etc.The management review shall include efforts to detect out-of-control conditions or alarm conditions. The process of reviewing the furnace data shall be documented and this requirement also applies to computerized data.

Are internal assessments being completed on an annual

basis, at a minimum, using AIAG HTSA?

The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG HTSA.

Is there a system in place to authorize reprocessing and is

it documented?

The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual.The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible.Any reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary heat treat modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.

Does the Quality Department review, address, and

document customer and internal concerns?

The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.

Is there a continual improvement plan applicable

to each process defined in the scope of the assessment?

The heat treater shall define a process for continual improvement for each heat treat process identified in the scope of the HTSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.

Does the Quality Manager or designee authorize the

disposition of material from quarantine status?

The Quality Manager is responsible for authorizing and documenting appropriate personnel to disposition quarantine material.

Are there procedures or work instructions available to the

heat treat personnel that define the heat treating

process?

There shall be procedures or work instructions available to heat treat personnel covering the heat treating process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.

Is management providing employee training for heat

treating?

The organization shall provide employee training for all heat treating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.

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Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page

1.17

1.18

1.19

Section 2 - Floor and Material Handling Responsibility

2.1

2.2

2.3

2.4

Is there a responsibility matrix to ensure that all key

management and supervisory functions are performed by

qualified personnel?

The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.

Is there a preventive maintenance program? Is maintenance data being

utilized to form a predictive maintenance program?

The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner.Company data, e.g., downtime, quality rejects, first-time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Furnaces and generators shall be scheduled for burn-out at frequencies determined by the organization (see Section 1 of the Process Tables).Maintenance data shall be collected and analyzed as part of a predictive maintenance program.

Has the Heat Treater developed a critical spare part list and are the parts available

to minimize production disruptions?

The heat treater shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.

Does the facility ensure that the data entered in the

receiving system matches the information on the customer's

shipping documents?

It is critical that all customer requirements and lot identification be adequately transferred to internal heat treat documents. The facility shall ensure that the data entered in the receiving system match the information on the customer's shipping documents. Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. Sometimes the material received does not precisely correspond to customer shipping documents. The facility shall have a detailed process in place to resolve receiving discrepancies.The requirements stated above also apply to captive heat treat departments. This process refers to receiving and shipping the parts in and out of the heat treat department.

Is product clearly identified and staged throughout the

heat treat process?

Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the heat treat process. Non-heat treated, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.

Is lot traceability and integrity maintained throughout all

processes?

Out-going lot(s) shall be traceable to the incoming lot(s).The discipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.

Are procedures adequate to prevent movement of non-conforming product into the production system?

The control of suspect or non-conforming product is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification, and tracking of material flow in and out of the hold area. A non-conforming hold area shall be clearly designated to maintain segregation of such material.

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Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page

2.5

2.6

2.7

2.8

2.9

2.10

Is there a system to identify trap points in the entire heat

treat process to reduce risk of mixed parts (inappropriate,

non-heat treated, or improperly heat treated

parts)?

Heat-treating furnaces and other processing equipment contain areas that have a risk of trapping or holding parts. Such trapping of parts can lead to damage, improperly processed parts or lot mixing/contamination. A system shall exist to identify trap points in the entire heat treat process to reduce risk of mixed parts (inappropriate, non-heat treated, or improperly heat treated parts). The heat treater shall have documented procedures to identify and monitor trap points for each process/equipment. Monitoring of potential trap points shall occur for every part changeover.

Are containers free of inappropriate material?

Containers handling customer product shall be free of inappropriate material. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming heat treated parts or inappropriate material contaminate the finished lot.

Is furnace loading specified, documented and controlled?

Furnace loading parameters shall be specified, documented, and controlled. Examples include feed rate, belt speed, number of parts per fixture, and load weight. Refer to Process Tables, Section 3.0, for frequency of checks.

Are operators trained in material handling,

containment action and product segregation in the

event of an equipment emergency including power

failure?

Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment actions related to all elements of the heat-treating process, e.g., loading, austentizing, quenching, tempering.

Is the handling, storage and packaging adequate to

preserve product quality?

Handling, storage, and packaging shall be adequate to preserve product quality. The heat treater’s furnace loading system, in-process handling, and shipping process shall be assessed for risk of part damage or other quality concerns.Some equipment includes conveyors and other moving components that may not be able to handle all part configurations. Other practices such as stacking of overloaded containers can also increase the risk of part damage.

Are plant cleanliness, housekeeping, environmental

and working conditions conducive to control and

improved quality?

Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality. The heat treater should evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for conditions that are detrimental to quality processing such as loose parts on floor, oil around quench tanks, inadequate plant lighting, smoke, etc.

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Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page

2.11

2.12

2.13

2.14

2.15

2.16

Section 3 - Equipment

3.1

3.2

Are parts free from contaminants that would be

detrimental to the heat treatment of the product?

Many heat-treated parts are subjected to surface finish or appearance operations such as plating or coating after heat treatment. Parts shall be free from contaminants that are detrimental to subsequent processes or the product. Pre-wash (if applicable) and post-wash parameters shall be monitored and documented. Oils and other contaminants or residues can be difficult to remove once subjected to the heat treatment process. Review the chemical supplier’s recommendation for cleaning the system. Parts shall be free of rust, burrs, chips, detrimental amounts of drawing compound, cutting fluids, rust preventing oils, lubricants, etc., prior to heat treat. Note: Refer to the appropriate heat treater's requirements and specifications to determine acceptability. Refer to Process Table, Section 5.0, for frequency of checking washer solutions.

Is the quenching system monitored, documented, and

controlled?

The quenching system shall be monitored, documented, and controlled. The temperature, agitation, level, concentration (if applicable), time in the quenchant, and additions shall be controlled to the heat treater's specifications. Refer to Process Tables, Sections 3.0 and 5.0, for frequency of checks. Computer-monitoring equipment, with alarms and alarm logs, satisfy the verification requirement. Quench delay tolerance and alarm is required for furnaces with integral quench tanks. Temper delay time shall be specified by the heat treater for parts that are quenched and tempered, e.g., carburizing, carbonitriding, neutral hardening, solution treating and aging.

Is soluble oil or other rust preventive monitored and controlled if applicable?

Parts are often dipped in or sprayed with rust preventive solutions immediately after the heat treating process. Soluble oil solutions or other rust preventive solutions shall be monitored and controlled, if applicable. The heat treater shall have and maintain documented tolerances for the solutions. Refer to Process Tables, Section 5.0, for frequency of checks.

Are process control parameters monitored per frequencies specified in

Process Tables?

Process control parameters shall be monitored per frequencies specified in Process Tables. Refer to Process Tables, Section 3.0. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log. Management review is required per Question 1.9.

Are In-Process / Final Test Frequencies performed as

specified in Process Tables?

In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables, Section 4.0.

Is product test equipment verified?

Product test equipment shall be verified. Test equipment shall be verified/calibrated per applicable customer-specific standard or per an applicable consensus standard such as those published by ASTM, DIN, EN, ISO, JIS, NIST, SAE etc. Verification/calibration results shall be internally reviewed, approved, and documented. Refer to Process Tables, Section 1.0, for frequency of checks.

Do furnaces, generators, and quench systems have proper process control equipment?

The heat-treat furnaces, generators, and quench systems shall have proper process controls and related equipment. Examples include temperature, carbon potential/dew point, gas flows, quench monitoring system including agitation, temperature control and quenching oil analysis, etc. as listed in the applicable Process Tables, Section 1.0.

Are process equipment calibrations and/or verification certified, posted, and current?

The calibration and certification of the process equipment shall be checked at regular specified intervals. Refer to the applicable Process Tables, Sections 1.0 and 2.0, for equipment calibration or certification time tables.

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Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page

3.3

3.4

3.5

3.6

3.7

Are thermocouples & protection tubes checked or

replaced per Process Tables?

The thermocouples and protection tubes shall be checked or replaced in compliance to a preventive maintenance schedule. Refer to the applicable Process Tables, Section 2.0.

Are temperature uniformity surveys performed per

requirements in Process Tables?

Temperature uniformity surveys shall be conducted per the requirements in the applicable Process Tables, Section 2.0. The frequency reductions allowed in AMS 2750D are not allowed under this document. Certain furnace designs, e.g., rotary retorts preclude direct temperature profiles. Alternate test methods per AMS 2750D 3.5.15 are acceptable for furnaces where temperature uniformity studies are not possible.

Is the variation of the furnace controlled thermocouple from

set point within the requirements in the Process

Table?

The variation between the furnace-control thermocouple and the set point temperature shall be within the limits defined in the applicable Process Tables, Section 2.0. This does not apply to the first zone of a multi-zone continuous furnace.

Are the process & equipment alarm checks being tested

quarterly or after any repair or rebuild?

The heat treater shall have a list of heat treat process and equipment alarms. These alarms shall be independently tested quarterly at a minimum, and after any repair or rebuild. These checks shall be documented.

Are generators and furnace atmospheres continuously monitored, automatically

controlled, and documented?

Generator and furnace atmosphere carbon potential/dew point shall be continuously monitored, automatically controlled, and documented. This requirement is specific to Process Table 1, Sections 1.0 and 3.0, for carburizing, carbonitriding, and neutral hardening. Continuous monitoring and automatic control of the carbon potential/dew point is required for all generators and atmosphere furnaces except rotary retort and shaker furnaces that preclude in situ control and monitoring. For rotary retort and shaker furnaces, the method described in AMS 2750D 3.5.15..2 "Property Surveys" shall be used to ensure adequate control of the furnace atmosphere. If generators are not used, the flow rates of the supplied atmosphere gases shall be monitored and controlled. The assessor shall verify the effectiveness of the atmosphere control system per customer requirements, the heat treater’s control plan, and internal procedures.

The atmosphere control system shall maintain the atmosphere dew point/carbon potential set point within the parameters specified in the control plan or internal procedures. The heat treater shall have a back-up method of checking the carbon potential/dew point. Examples are dew point, electrical wire resistance, gas analysis, shim stock, carbon bar, etc. The automatic and continuous atmosphere control system shall consist of sensors such as oxygen probes or on-line Infrared (IR) gas analysis. See Process Table A, Sect. 3.0 for verification frequencies.

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Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page

3.8

3.9

3.10

3.11

3.12

When the back-up verification check of the atmosphere does not agree or correlate within

pre-established limits with the primary control method

(carbon potential/dew point reading), is correlation of the

carbon-bearing atmosphere to the primary control method re-

established?

This issue is specific to Process Table 1, carburizing, carbonitriding, and neutral hardening. When the back-up verification check of the atmosphere does not agree or correlate within pre-established limits with the primary control method (carbon potential/dew point reading), the heat treater shall resolve the out-of-limit discrepancy. The back-up atmosphere monitoring system reading and the automatically controlled atmosphere dew point/carbon potential reading shall be maintained within the correlation limits specified in the control plan or internal procedures. These range tolerances vary with the specific heat treat process and the equipment used. The heat treater shall make appropriate technical adjustments and corrections and then re-establish/demonstrate the correlation of the actual atmosphere carbon potential/dew point reading to the primary control and back-up atmosphere reading. The range tolerances for correlation between the two readings shall be in the control plan or internal procedures. The back-up carbon potential/dew point reading shall be established using one or more of the following methods: • Carbon bar or slug• Shim stock• 3-gas analyzer• Dew point• Hot wire resistance

Are all ammonia lines equipped with quick

disconnects or a three valve fail safe vent system?

All ammonia lines to furnaces shall be equipped with quick disconnects or a three-valve fail-safe vent system. Normal valves may allow ammonia to leak through even when they are closed. This can be undesirable and detrimental in heat treat processes not specifying/requiring ammonia.• A quick disconnect shall be present in any ammonia line going to a furnace. This line shall be disconnected after carbonitriding (or any other process using ammonia) before another heat treating operation not specifying/using ammonia begins.• An alternative three-valve ammonia "fail-safe" vent system is permitted. See the definition “Three Valve Fail-Safe Vent” and diagram in the glossary.• Documentation shall show when ammonia lines are disconnected for non-ammonia bearing atmosphere processes.

For fasteners and small metal parts, is a minimum of 3 hours

allocated for an oxidizing burn-out prior to processing

product not requiring ammonia?

This is applicable to fasteners and small metal parts. The heat treater shall perform a minimum 3 hours oxidizing burn-out prior to processing product not requiring ammonia as an addition. Ammonia pick-up can be undesirable in parts and heat treat processes not specifying/requiring ammonia as an addition. Log book, data logger, or other records shall document the actual oxidizing burn-out time and that sufficient time has been allocated to remove ammonia from the furnace prior to processing parts in heat treat processes not specifying ammonia.

Do all atmosphere furnaces and generators have flow scopes or flow meters for all gases?

All atmosphere furnaces and generators (output trim/adjustment gas) shall have flow scopes or flow meters for all gases. Flow scopes and meters shall be periodically serviced per the heat treater's preventive maintenance program. Cleaning and proper re-assembly procedures shall be documented.

For threaded fasteners, are all continuous belt furnaces equipped with sight glass

inspection ports and infrared pyrometers at discharge end of the hardening furnace?

Infrared temperature pyrometers are required at the exit end of continuous belt furnaces running threaded fasteners to monitor for under temperature parts. The temperature alarm shall be within 28C (50F) of the furnace set point temperature. Results shall be strip charted or continuously data logged. Infrared (IR) units shall be calibrated annually at a minimum and certified. All sight glasses shall be cleaned per the preventive maintenance schedule.

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3.13

3.14

FOR INDUCTION HEAT TREATING

3.15

3.16

3.17

3.18 Is quench system automatic?

3.19

Is salt chemistry in the austenitizing salt bath

monitored?

Applicable to ferritic-nitrocarburizing, austempering, and neutral hardening in salt.The heat treater shall check the salt chemistry in the austentizing salt bath, or part decarburization, daily. Refer to the applicable Process Tables, Section 3.0, for frequency of checks.

Is the quenching medium analyzed?

The heat treater shall periodically have the quenching medium analyzed for specific quenching characteristics, e.g., cooling curve, water content, salt concentration, as specified in the applicable Process Tables, Section 5.0.• The quench media characteristic tolerances shall be specified by the quench medium supplier or the heat treater.• Analysis shall be reviewed for conformance by the heat treater. This review shall be documented.

Is the positioning of each part being controlled?

A method to detect proper part position, such as the use of proximity switches, optical sensors, mechanical probes, etc., is required for each part.

Does the heat treater control the energy or power for each part?

The heat treater shall control the energy or power for each part.• A signature monitor for each machine is preferred. A signature monitor gives the energy unit (voltage, kilowatt, etc.) vs. time or distance (for scanning systems).• An energy monitor or equivalent is acceptable if approved by the authorized customer representative.

Does the supplier have a coil management system? Coil refers to the heating coil and the quench plenum.

The heat treater shall have a coil management system. Coil refers to the heating coil and the quench plenum.• Spare coils for each part shall be available on-site.• Coils shall conform to the approved original design.• Engineering change approval from the customer is required whenever the coil design is changed.

The quench system shall be an automatic operation. No manual quenching is allowed unless specifically approved by the authorized customer representative. Quenching shall be automatically initiated and controlled.

Does each lot of parts have first piece set-up?

The heat treater shall perform first piece set-up for each lot of parts

Page 37: Supplier Evaluation (QVR)Rev6 0112

Section 4 - Job Audit

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Material:

Heat Treat Requirements:

Question # Job Audit Question

4.1

N/A

4.2 1.5 N/A

4.3

4.4

4.5 2.1

4.6

4.7

4.8 2.15

4.8.1 Requirement: (1)Test Method:Test frequency or quantity:Selection of samples:Specification:

4.8.2 Requirement: (2)Test Method:Test frequency or quantity:Selection of samples:Specification:

4.8.3 Requirement: (3)Test Method:Test frequency or quantity:Selection of samples:Specification:

4.8.4 Requirement: (4)Test Method:Test frequency or quantity:Selection of samples:Specification:

Operator or Inspector Responsibilities4.9

4.10

4.11

RelatedHTSA Question #

Customer or Internal Requirement

Job (Shop) Order or Reference Documentation

Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

Are contract review, advance quality planning, FMEA, control plans, etc., performed by qualified individuals?

1.21.31.4

1.17

Does the heat treat facility have the customer specifications for the part?

Is a shop traveler created to meet customer requirements?

1.62.1

Is material identification (part numbers, lot numbers, heat numbers, contract numbers, etc.) maintained throughout the heat treat process?

2.22.32.4

Is there documented evidence of Receiving Inspection?

Are the Loading / Racking requirements identified?

1.62.72.9

Is the proper recipe or process specification (cycle times, temperature, atmosphere, etc.) used? Refer to Process Tables, Section 3.0, for specific parameters. List parameters that were verified in this audit in the spaces provided below.

1.51.62.1

2.142.15

What are the product inspection requirements?

Were appropriate process steps signed off?

1.42.22.3

2.14

Were all inspection steps, as documented in the control plan performed?

1.21.4

Were steps/operations performed that were not documented in the control plan?

1.21.41.6

Cover PageCover Page Index PageIndex Page

Page 38: Supplier Evaluation (QVR)Rev6 0112

Section 4 - Job Audit

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Material:

Heat Treat Requirements:

Question # Job Audit QuestionRelated

HTSA Question #Customer or Internal

Requirement

Job (Shop) Order or Reference Documentation

Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

Cover PageCover Page Index PageIndex Page

4.12

4.13 1.11

4.14

4.15 1.17

4.16

Packaging Requirements

4.17 2.9

4.18 2.9

Shipping Requirements

4.19 Were the parts properly identified?

4.20

If additional steps were performed, were they authorized?

1.21.41.6

1.111.17

Does the governing specification allow reprocessing or rework?

If the order was certified, did the certification accurately reflect the process performed?

2.142.15

Was the certification signed by an authorized individual?

Are the parts and containers free of inappropriate objects or contamination?

2.62.11

Are packaging requirements identified?

Are parts packaged to minimize mixed parts (for example, parts packed over height of container)?

2.32.9

Were the containers properly labeled?

2.32.9

Page 39: Supplier Evaluation (QVR)Rev6 0112

Assessor(s) shall have the following specific experience to conduct the HEAT TREAT SYSTEM ASSESSMENT:

1 Be an experienced quality management system (QMS) internal auditor (for example,ISO/TS 16949-2002, ISO 9001:2000).

2 Assessor shall possess heat treating knowledge. Evidence shall include a minimum of 5years experience in heat treating or a combination of formal metallurgical education and heat treating experience totaling a minimum of 5 years.

3 Assessor shall possess knowledge of and be familiar with the application of automotivequality core tools including statistical process control, measurement systems analysis,part approval, failure mode and effects analysis, and advanced quality planning.

Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in item # 1 above.

Index PageIndex PageCover PageCover Page

Page 40: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators

1.0 PROCESS AND TEST EQUIPMENT REQUIREMENTSA1.1 Yes Yes Yes

A1.2 Yes Yes

A1.3 1.18 Yes Yes Yes

A1.4 3.2 Yes Yes -----

A1.5 3.2 ----- ----- -----

A1.6 3.2 ----- ----- -----

A1.7 3.2 ----- ----- -----

A1.8 3.2 Yes Yes Yes

A1.9 2.16 ----- ----- -----

A1.10 2.16 ----- ----- -----

A1.11 3.2 ----- ----- -----

2.0 PYROMETRY

A2.1 Yes Yes Yes

A2.2 Yes Yes Yes

PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".

Related HTSA Question #

Batch Furnace

ContinuousFurnace *

3.13.7

All furnaces, generators and quench systems shall have temperature indicating instruments.

3.13.7

Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc.

Yes

A program for furnace and generator burnout is required (applies to carbon bearing atmospheres).

Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.

Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential in furnaces, shall be calibrated annually at a minimum.

Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use.

Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum.

Oxygen probe controllers shall be calibrated quarterly at a minimum.

All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.

Files shall be verified daily (or prior to use) with provers per SAE J864.

Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.

3.23.3

Thermocouples and calibration of thermocouples shall conform to AMS 2750D.

3.23.3

Instrument Calibration per AMS 2750D shall be quarterly at a minimum.

Frequency reductions per AMS 2750D are not allowed.

Cover PageCover Page Index PageIndex Page

Page 41: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators

PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".

Related HTSA Question #

Batch Furnace

ContinuousFurnace *

Cover PageCover Page Index PageIndex Page

A2.3 Yes Yes Yes

A2.4 3.4 Yes -----

A2.5 3.5 Yes -----

A2.6 3.5 Yes -----

A2.7 3.2 -----

3.0 PROCESS MONITOR FREQUENCIES

3.23.3

CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C). (1) The CTS shall be within an operating temperature range of +/- 5C (or +/-10F) of the CTTS. This check shall be performed monthly. (2) Within the operating temperature range the difference between the CTS and R-T/C readings shall be no more than +/- 1C (or +/-2F) as determined at the time of the most recent temperature uniformity survey. This check shall be performed weekly. Any actions to correct a failing reading or validate a test result shall be documented. Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.

Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed every two years at a minimum. Protection Tubes shall be visually checked at the same frequency as thermocouples.

Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be annual and after major rebuild.

Temperature uniformity tolerance for hardening furnaces shall be +/- 14 C (or +/- 25 F). Temperature uniformity tolerance for tempering furnaces shall be +/- 11 C (or +/- 20 F).

Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range of the Qualified Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.

Frequency reductions per AMS 2750D are not allowed.

Yes - In Qualified Work Zone

Recorded temperature(s) for austentizing processes shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).

Yes - In Qualified Work Zone

Recorded temperature(s) for tempering and precipitation hardening processes shall be controlled within +/- 6C (or +/- 10F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).

Yes - In Qualified Work Zone

Infrared pyrometers shall be calibrated to a black body furnace annually.

Page 42: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators

PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".

Related HTSA Question #

Batch Furnace

ContinuousFurnace *

Cover PageCover Page Index PageIndex Page

A3.1 Monitor primary temperature control instrument(s). Each Shift

A3.2 Monitor generator atmospheres. ----- ----- Continuous

A3.3 Monitor primary furnace atmosphere control(s)**. -----

A3.4 Daily Daily Daily

A3.5 Daily Daily -----

A3.6 Quench Media Process Parameters

- Temperature -----

- Quench Level Daily Daily -----

- Agitation -----

A3.7 Monitor time in furnace, cycle time or belt speed. Each batch -----

A3.8 Monitor load size or fixturing or loading rate as applicable. Each batch -----

A3.9 Each batch -----

4.0 IN-PROCESS/FINAL TEST FREQUENCIES

A4.1 Microstructure Daily per furnace Daily per furnace -----

A4.2 Surface hardness Each batch Every 2 hours minimum -----

A4.3 Core hardness (when specified) Each batch Every 4 hours -----

A4.4 Case depth (when specified) Each batch Every 4 hours -----

5.0 QUENCHANT AND SOLUTION TEST FREQUENCIESA5.1 Polymer Quench Media

- Concentration Daily Daily -----

1.42.14

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

1.42.143.7

1.42.143.7

Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

1.42.143.7

Verify primary atmosphere control method by back-up method**.

1.42.143.13

For austentizing salt baths: Salt chemistry (soluble oxides) or decarburization on the parts shall be checked daily.

1.42.12

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

- Daily visual check is required.

- Monitor each load in the absence of an alarm system.

- Daily visual check is required.

- Monitor every 2 hours in the absence of an alarm system.

1.42.14

Twice/shift & after any change in the belt speed.

1.42.7

Twice/shift & after any change in loading rate.

1.42.12

Quench Delay Time -Alarm system shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.

Each basket for pusher-type continuous furnaces. Not applicable for belt furnaces.

1.42.15

1.42.15

1.42.15

1.42.15

2.123.14

Page 43: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators

PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".

Related HTSA Question #

Batch Furnace

ContinuousFurnace *

Cover PageCover Page Index PageIndex Page

A5.1

Every six months Every six months -----

A5.2 Water Quench Media- Suspended solids Every six months Every six months -----

A5.3 Salt Quench Media- Analysis & Contaminants Every six months Every six months -----

A5.4 Brine or Caustic Quench Media

Daily Daily -----

- Suspended solids Every six months Every six months -----A5.5 Oil Quench Media

Quarterly Quarterly -----

A5.6 2.13 Rust Preventive - Soluble Oil

- Concentration 2x / week 2x / week -----A5.7 2.11 Washers

- Concentration of cleaner Daily Daily -----Each shift Each shift -----

2.123.14

- Quenchability Check; e.g., cooling curve, viscosity, or titration

2.123.14

2.123.14

2.123.14 - Concentration and/or Specific

Gravity.

2.123.14 - Water content, suspended solids,

viscosity, cooling curve, total acid, and flash point.

- Temperature of solution (required if temperature is specified to be above ambient temperature).

Page 44: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators Salt Bath

1.0

B1.1 Yes Yes Yes Yes

B1.2 Yes Yes

B1.3 1.18 Yes Yes Yes -----

B1.4 ----- ----- ----- Yes

B1.5 3.2 Yes Yes ----- -----

B1.6 3.2 ----- ----- ----- -----

B1.7 2.16 ----- ----- ----- -----

B1.8 2.16 ----- ----- ----- -----

B1.9 3.2 ----- ----- ----- -----

2.0 PYROMETRY B2.1 Yes Yes Yes Yes

B2.2 Yes Yes Yes Yes

PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

PROCESS AND TEST EQUIPMENT REQUIREMENTS

3.13.7

All furnaces, generators and quench systems shall have temperature indicating instruments.

3.13.7

Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc.

Yes Yes - For

temperature only

A program for furnace and generator burnout is required. Not required for retort gas nitriding.

3.123.13

For austentizing salt baths: Salt chemistry (soluble oxides) or decarburization on the parts shall be checked daily.

Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.

Dew pointers and gas analyzers, used to verify proper atmosphere in furnaces, shall be calibrated annually at a minimum.

All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.

Files shall be verified daily (or prior to use) with provers per SAE J864.

Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.

3.23.3

Thermocouples and calibration of thermocouples shall conform to AMS 2750D.

3.23.3

Instrument Calibration per AMS 2750D shall be quarterly at a minimum.

Frequency reductions per AMS 2750D are not allowed.

Index PageIndex PageCover PageCover Page

Page 45: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators Salt Bath

PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

Index PageIndex PageCover PageCover Page

B2.3 Yes Yes Yes Yes

B2.4 3.4 Yes ----- Yes

3.23.3

CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C).

(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly.

(2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/- 1C (or +/- 2F) of their relationship determined at the time of the most recent temperature uniformity survey; this checked shall be performed weekly.

Any actions to correct a failing reading or validate a test result shall be documented.

Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.

Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed every two years at a minimum.

Protection Tubes shall be visually checked at same frequency as thermocouples.

Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be annual and after major rebuild.

Temperature uniformity tolerance shall be +/- 9 C (15 F).

Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range of the Qualified Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.

Frequency reductions per AMS 2750D are not allowed.

Yes - In Qualified Work Zone

Page 46: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators Salt Bath

PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

Index PageIndex PageCover PageCover Page

B2.5 3.5 Yes ----- Yes

B2.6 3.2

3.0 PROCESS MONITOR FREQUENCIESB3.1 Monitor primary temperature control instrument(s). Each Shift

B3.2 Monitor generator atmospheres, if applicable. ----- ----- Continuous -----

B3.3 Monitor primary furnace atmosphere control(s). ----- Daily

B3.4 Every 4 hours Daily N/A

B3.5 Gas ratios for ferritic nitrocarburizing shall be checked. Each batch

B3.6 ----- ----- ----- Daily

B3.7 Quench Media Process Parameters

Recorded temperature(s) shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).

Yes - In Qualified Work Zone

Infrared pyrometers shall be calibrated to a black body furnace annually .

1.42.14

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

Every 2 hours & after any change

1.42.143.7

1.42.143.7

Each batch (rotary furnaces only) or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

1.43.7

Dissociation of ammonia shall be checked in gas nitriding.

Each batch and every 4 hours minimum

1.43.7

Every 2 hours minimum

1.42.143.13

Check salt chemistry (soluble oxides) in salt baths used for austenitizing, or decarburization on the parts.

1.42.12

Page 47: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators Salt Bath

PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

Index PageIndex PageCover PageCover Page

B3.7

- Temperature -----

- Quench Level Daily Daily ----- Daily- Agitation ----- Daily

B3.8 Monitor time in furnace, cycle time or belt speed. Each batch ----- Each batch

B3.9 Each batch ----- Each batch

B3.10 Each batch ----- Each batch

4.0 IN-PROCESS/FINAL TEST FREQUENCIES B4.1 Microstructure Daily per furnace -----

B4.2 Surface hardness Each batch ----- Each batch

B4.3 Core hardness (when specified) Each batch Every 4 hours ----- Each batch

B4.4 Case depth (when specified) Each batch Every 4 hours ----- Each batch

5.0

Quench Media Controls If ApplicableB5.1 Polymer Quench Media

- Concentration Daily Daily ----- -----Every six months ----- -----

B5.2 Water Quench Media- Suspended solids Every six months ----- -----

B5.3 Salt Quench Media- Analysis & Contaminants Every six months -----

B5.4 Brine or Caustic Quench Media

1.42.12 Each batch or

continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

- Daily - Monitor each load in the absence of an alarm system.

- Daily - Monitor every 2 hours in the absence of an alarm system.

1.42.14

Twice/shift & after any change in the belt speed.

1.42.7

Monitor load size or fixturing or loading rate as applicable.

Twice/shift & after any change in loading rate.

1.42.12

Quench Delay Time if applicable -Alarm system shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.

Each basket if applicable.

1.42.15

Daily per furnace

Daily per furnace

1.42.15

Every 2 hours minimum

1.42.15

1.42.15

QUENCHANT AND SOLUTION TEST FREQUENCIES

2.123.14

- Quenchability Check; e.g., cooling curve, viscosity, or titration.

Every six months

2.123.14 Every six

months

2.123.14 Every six

monthsEvery six months

2.123.14

Page 48: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators Salt Bath

PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

Index PageIndex PageCover PageCover Page

B5.4 Daily Daily ----- -----

- Suspended solids Every six months ----- -----

B5.5 Oil Quench MediaQuarterly Quarterly ----- -----

B5.6 2.13 Rust Preventive - Soluble Oil- Concentration 2x / week 2x / week ----- 2x / week

B5.7 2.11 Washers- Concentration of cleaner Daily Daily ----- Daily

Each shift Each shift ----- Each shift

2.123.14 - Concentration and/or Specific

Gravity

Every six months

2.123.14 - Water content, suspended solids,

viscosity, cooling curve, total acid, and flash point.

- Temperature of solution (required if temperature is specified to be above ambient temperature).

Page 49: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps

1.0

C1.1 Yes Yes Yes

C1.2 Yes Yes

C1.3 2.16 ----- ----- -----

C1.4 3.2 Yes Yes Yes

C1.5 3.2 ----- ----- -----

2.0 PYROMETRY C2.1 Yes Yes Yes

C2.2 Yes Yes Yes

PROCESS TABLE C - Aluminum Heat Treating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Solution Treating and Aging Furnaces

Continuous Solution Treating and Aging

Furnaces

Annealing Furnace

PROCESS AND TEST EQUIPMENT REQUIREMENTS

3.13.7

All furnaces and quench systems shall have temperature indicating instruments.

3.13.7

Continuous strip charts and/or data loggers are required for temperature sensors.

Yes

All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.

Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.

Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.

3.23.3

Thermocouples and calibration of thermocouples shall conform to AMS 2750D.

3.23.3

Instrument Calibration per AMS 2750D shall be quarterly at a minimum.

Frequency reductions per AMS 2750D are not allowed.

Cover PageCover Page Index PageIndex Page

Page 50: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps

PROCESS TABLE C - Aluminum Heat Treating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Solution Treating and Aging Furnaces

Continuous Solution Treating and Aging

Furnaces

Annealing Furnace

Cover PageCover Page Index PageIndex Page

C2.3 Yes Yes Yes

C2.4 3.4 Yes Yes

3.23.3

CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C).

(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly.

(2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/- 1C (or +/- 2F) of their relationship determined at the time of the last temperature uniformity survey; this checked shall be performed weekly.

Any actions to correct a failing reading or validate a test result shall be documented.

Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.

Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed bi-annually every two years at a minimum.

Protection Tubes shall be visually checked at same frequency as thermocouples.

Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be quarterly and after major rebuild.

Temperature uniformity tolerance for solution treating and aging furnaces shall be +/- 6 C (or +/- 10 F). Temperature uniformity tolerance for annealing furnaces shall be +/- 14 C (or +/- 25 F).

Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range of the Qualified Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.

Frequency reductions per AMS 2750D are not allowed.

Yes - In Qualified Work Zone

Page 51: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps

PROCESS TABLE C - Aluminum Heat Treating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Solution Treating and Aging Furnaces

Continuous Solution Treating and Aging

Furnaces

Annealing Furnace

Cover PageCover Page Index PageIndex Page

C2.5 3.5 Yes -----

C2.6 3.5 ----- ----- Yes

C2.7 3.2

3.0 PROCESS MONITOR FREQUENCIESC3.1 Monitor primary temperature control instrument(s).

C3.2 Quench Media Process Parameters-----

- Quench Level Daily Daily ------ Agitation -----

C3.3 Monitor process cycle time Each batch Each batch

C3.4 Monitor load size or fixturing as applicable. Each batch Each batch

C3.5 Each batch Each load -----

4.0 IN-PROCESS/FINAL TEST FREQUENCIES

Recorded temperature(s) shall be controlled within +/- 6C (or +/- 10F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).

Yes - In Qualified Work Zone

Recorded temperature(s) shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).

Infrared pyrometers shall be calibrated to a black body furnace annually.

1.42.14

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

1.42.12 - Heat treater shall specify temperature range based

on product form and material. Temperature shall be monitored as noted.

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

- Daily visual check is required.

- Monitor each load in the absence of an alarm system.

- Daily visual check is required.

- Monitor every 2 hours in the absence of an alarm system.

1.42.14

Twice/shift & after any change in the indexing speed.

1.42.7

Twice/shift & after any change in loading rate.

1.42.12

Quench Delay Time -Quench delay time shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.

Page 52: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps

PROCESS TABLE C - Aluminum Heat Treating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Solution Treating and Aging Furnaces

Continuous Solution Treating and Aging

Furnaces

Annealing Furnace

Cover PageCover Page Index PageIndex Page

C4.1 Hardness or tensile testing (post aging). Each batch Every 4 hours

5.0

C5.1 Polymer Quench Media- Concentration Daily Daily ------ Suspended solids Every six months Every six months -----

Every six months Every six months -----

C5.2 Water Quench Media- Suspended solids Every six months Every six months -----

C5.3 2.11 Washers- Concentration of cleaner Daily Daily Daily

Each shift Each shift Each shift

1.42.15

Each batch or every 4 hours for continuous furnaces

QUENCHANT AND SOLUTION TEST FREQUENCIES

2.123.14

- Quenchability Check; e.g., cooling curve, viscosity, or titration.

2.123.14

- Temperature of solution (required if temperature is specified to be above ambient temperature).

Page 53: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Per Coil

1.0

D1.1 --- Per customer requirementD1.2 2.16 -----

D1.3 2.16 -----

D1.4 3.2 -----

2.0 PYROMETRY D2.1 3.2 -----

3.0 PROCESS MONITORING FREQUENCIES

D3.1 Quench Media Process Parameters

- Temperature

- Quench Level Daily

- Quench Pressure and Flow

PROCESS TABLE D - Induction Heat Treating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.----- indicate "not applicable".

Related HTSA Question #

PROCESS AND TEST EQUIPMENT REQUIREMENTS

All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.

Files shall be verified daily (or prior to use) with provers per SAE J864.

Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified each shift (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.

Infrared pyrometers shall be calibrated to a black body furnace annually.

All process parameters shall be checked the beginning of every shift, tool change, or any equipment repair. In absence of process parameter alarms, also check process parameters at end of shift or lot (whichever is the greater frequency).

1.42.12 Alarm system for high and low

temperature is required.

- Quench pressure and flow may checked at manifold. Quench flow shall be checked visually at each coil.- In the absence of an alarm system, monitor every 2 hours or after any change.

Index PageIndex PageCover PageCover Page

Page 54: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Per Coil

PROCESS TABLE D - Induction Heat Treating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.----- indicate "not applicable".

Related HTSA Question #

Index PageIndex PageCover PageCover Page

D3.2 Monitor cycle time

D3.3

4.0

D4.4 Induction pattern length

D4.5 Total or Effective Case depth

D4.6 Surface hardness

D4.7 Core hardness (when specified)

1.42.14

Check cycle time at start up and after any process change.

1.42.143.16

Monitor: 1) Volts or Amps, and2) KilowattsUse of an energy monitor or signature monitor satisfies 1) and 2).

- This requirement applies to each power supply (not per coil). - In the absence of an alarm system, monitor every 2 hours or after any change.

IN-PROCESS/FINAL TEST FREQUENCIES

Production Setup or Coil Change - Per Coil(1st Piece Inspection)

1.42.15

1 part at start-up, end of production run, and every 4 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)

1.42.15

1 part at start-up, end of production run, and 1 part per 8 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)

1.42.15

1 part at start-up, end of production run, and every 4 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)

1.42.15

1 part at start-up, end of production run, and every 4 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)

Page 55: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Per Coil

PROCESS TABLE D - Induction Heat Treating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.----- indicate "not applicable".

Related HTSA Question #

Index PageIndex PageCover PageCover Page

D4.8 Microstructure

5.0

Quench Media Controls If ApplicableD5.1 Polymer Quench Media

- Concentration Once per dayMonthly

D5.2 Water Quench Media- Suspended solids Quarterly

D5.3 Brine or Caustic Quench MediaMonthly

- Suspended solids QuarterlyD5.4 2.13 Rust Preventive - Soluble Oil

- Concentration 2x / weekD5.5 2.11 Washers

- Concentration of cleaner DailyEach shift

1.42.15

1 part at start-up, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)

QUENCHANT AND SOLUTION TEST FREQUENCIES

2.123.14

- Quenchability Check; e.g., cooling curve, viscosity, or titration

2.123.14

2.123.14 - Concentration and/or Specific

Gravity

- Temperature of solution (required if temperature is specified to be above ambient temperature).

Page 56: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators

1.0 PROCESS AND TEST EQUIPMENT REQUIREMENTS

E1.1 Yes Yes Yes

E1.2 Yes Yes

E1.3 3.2 Yes Yes -----

E1.4 3.2 ----- ----- -----

E1.5 3.2 ----- ----- -----

E1.6 3.2 ----- ----- -----

E1.7 3.2 Yes Yes Yes

E1.8 2.16 ----- ----- -----

2.0 PYROMETRY

E2.1 Yes Yes Yes

E2.2 Yes Yes Yes

PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".

Related HTSA Question #

Batch Furnace

ContinuousFurnace *

3.13.7

All furnaces, generators and quench systems (where applicable) shall have temperature indicating instruments.

3.13.7

Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc.

Yes

Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.

Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential in furnaces, shall be calibrated annually at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.

Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use. This is applicable when used in controlling carbon-bearing atmospheres.

Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.

Oxygen probe controllers shall be calibrated quarterly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.

All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.

3.23.3

Thermocouples and calibration of thermocouples shall conform to AMS 2750D.

3.23.3

Instrument Calibration per AMS 2750D shall be quarterly at a minimum.

Frequency reductions per AMS 2750D are not allowed.

Cover PageCover Page Index PageIndex Page

Page 57: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators

PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".

Related HTSA Question #

Batch Furnace

ContinuousFurnace *

Cover PageCover Page Index PageIndex Page

E2.3 Yes Yes Yes

E2.4 3.4 Yes -----

E2.5 3.5 Yes -----

3.0 PROCESS MONITOR FREQUENCIES

3.23.3

CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C).

(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly.

(2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/- 1C (or +/- 2F) of their relationship determined at the time of the most recent temperature uniformity survey; this checked shall be performed weekly.

Any actions to correct a failing reading or validate a test result shall be documented.

Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.

Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed bi-annually every two years at a minimum.

Protection Tubes shall be visually checked at same frequency as thermocouples.

Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be annual and after major rebuild.

Temperature uniformity tolerance for hardening furnaces shall be +/- 14 C (or +/- 25 F). Temperature uniformity tolerance for tempering furnaces shall be +/- 11 C (or +/- 20 F).

Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range of the Qualified Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.

Frequency reductions per AMS 2750D are not allowed.

Yes - In Qualified Work Zone

Recorded temperature(s) shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).

Yes - In Qualified Work Zone

Page 58: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Generators

PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".

Related HTSA Question #

Batch Furnace

ContinuousFurnace *

Cover PageCover Page Index PageIndex Page

E3.1 Monitor primary temperature control instrument(s). Each Shift

E3.2 Monitor generator atmospheres ----- ----- Continuous

E3.3 Monitor primary furnace atmosphere control(s)**. -----

E3.4 Daily Daily Daily

E3.5 Daily Daily -----

E3.6 Monitor time in furnace, cycle time or belt speed. Each batch -----

E3.7 Each batch -----

4.0 IN-PROCESS/FINAL TEST FREQUENCIES

E4.1 Microstructure (when specified) Daily per furnace Daily per furnace -----

E4.2 Surface hardness (when specified) Each batch Every 2 hours minimum -----

E4.3 Core hardness (when specified) Each batch Every 4 hours -----

5.0 SOLUTION TEST FREQUENCIES

E5.1 2.13 Rust Preventive - Soluble Oil

- Concentration 2x / week 2x / week -----

E5.2 2.11 Washers

- Concentration of cleaner Daily Daily -----

Each shift Each shift -----

1.42.14

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

1.42.143.7

1.42.143.7

Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

1.42.143.7

Verify primary atmosphere control method by back-up method**.

1.42.143.13

For salt baths: check salt chemistry (soluble oxides) in salt baths or decarburization on the parts.

1.42.14

Twice/shift & after any change in the belt speed.

1.42.7

Monitor load size or fixturing or loading rate as applicable.

Twice/shift & after any change in loading rate.

1.42.15

1.42.15

1.42.15

- Temperature of solution (required if temperature is specified to be above ambient temperature).

Page 59: Supplier Evaluation (QVR)Rev6 0112

CQI-11 PLATING SYSTEM ASSESSMENT

Instructions for completing the Cover Sheet

1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physicallocations in the same general area. If there is a separate management team (Quality Manager andPlating Specialist) or different management system, then these locations shall be considered asseparate facilities.

2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.

3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.

4 Fax number: The fax number of the facility.

5 Number of Plating Employees at this Facility: The number of employees, salaried and hourly, associated with the plating operation at this facility.

6 Captive Plater (Y/N): Enter "Y" if this facility Plates components for their own company. Enter"N" if the company does not Plate any components for their own company.

7 Commercial Plater (Y/N): Enter "Y" if this facility Plates components for companies other thantheir own company. Enter "N" if this facility does not Plate any components for other companies.

8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.Example: May 3 -- 4, 2006.

9 Date of Previous Assessment: List the date of the previous CQI-11 Special Process: PlatingSystem Assessment of this facility.

10 Type(s) of Plating at this Facility: Place a checkmark to designate the Plating process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the PlatingSystem Assessment.

11 Current Quality Certification(s): the plater shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.

12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the plater shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 5, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.

13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the plater's organization.

14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).

15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.

16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.

17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.

Cover PageCover Page Index PageIndex Page

Page 60: Supplier Evaluation (QVR)Rev6 0112

Special Process: Plating System Assessment

Facility Name:Address:

Phone Number: Type(s) of Plating Processing at this Facility:Fax Number: Process Table A

ZincNumber of Plating Employees at this Facility: Zinc Alloy Plating

Captive Plater (Y/N): Process Table BCommercial Plater (Y/N):

Date of Assessment: Process Table C

Date of Previous Assessment:Process Table DDecorative Plating

Process Table EMechanical Plating

Process Table FEquipmentProcess Equipment

Current Quality Certification(s):

Date of Re-assessment (if necessary):

Personnel Contacted:Name: Title: Phone: Email;

0 00 00 00 0

Auditors/Assessors:Name: Company: Phone: Email:

0000

Number of "Not Satisfactory" Findings:

Number of "Needs Immediate Action" Findings:

Number of "Fail" Findings in the Job Audit(s):

Surface Conditioning of Metals for Decorative Plating

Surface Conditioning of ABS & PCABS Plastics for Decorative Plating

Cover PageCover Page Index PageIndex Page

Page 61: Supplier Evaluation (QVR)Rev6 0112
Page 62: Supplier Evaluation (QVR)Rev6 0112

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A Satisfactory

Section 1 - Management Responsibility and Quality Planning

1.1

1.2

1.3

1.4

Question Number

Not Satisfactory

Needs Immediate Action

Is there a dedicated and qualified plating person on-site?

To ensure readily available expertise, there shall be a dedicated and qualified plating person on the site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the postition including chemical and plating knowledge. The qualifications shall include a minimum of 5 years experience in plating and surface finishing or a combination of formal chemistry/chemical engineering education and plating experience totaling a minimum of 5 years.

Does the plater perform advanced quality planning?

The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The plater shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.

Are plater FMEA's up to date and reflecting current processing?

The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEAs are updated to reflect current part quality status.The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key plating process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.

Are finish process control plans up to date and reflecting current processing?

The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls. The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key plating process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEAs. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and Frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables.

Index PageIndex PageCover PageCover Page

Page 63: Supplier Evaluation (QVR)Rev6 0112

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory

Needs Immediate Action

Index PageIndex PageCover PageCover Page

1.5

1.6

1.7

Are all plating related and referenced specifications current and available? For example: SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler.

To ensure all customer requirements are both understood and satisfied, the organization shall have all related plating and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards and specifications and changes based on customer-required schedule. This process shall be executed as soon as possible and shall not exceed two weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks.

Is there a written process specification for all active processes?

The plater shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, rectifier settings, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control. All active processes should have a written process specification. These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.

Has a valid product capability study been performed initially and after process change?

To demonstrate each process is capable of yielding acceptable product the organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, and after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all plating processes per line as defined in scope of work and in accordance with customer requirements. Capability study techniques shall be appropriate for the plating product characteristics, e.g. plate thickness, corrosion resistance, etc.. Any specific customer requirements shall be met. In the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to be followed in case capability indices fall outside customer requirements or established ranges.

Page 64: Supplier Evaluation (QVR)Rev6 0112

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory

Needs Immediate Action

Index PageIndex PageCover PageCover Page

1.8

1.9

1.10

1.11

1.12

1.13

1.14

1.15

Does the plater collect and analyze data over time, and react to this data?

The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time. Methods of analysis shall include ongoing trend or historical data analysis of special product or process parameters. The organization shall determine which parameters to include in such analysis.

Does management review and verify bake oven logs for parts requiring hydrogen embrittlement relief every 24 hours?

Management shall review the oven monitoring systems/logs at intervals not to exceed 24 hours or prior to parts being released for shipment. The plater shall have reaction plans for non-conformances to process requirements. This is to contain, at minimum, requirements for quarantining material and notifying customer.

Are internal assessments being completed on an annual basis, at a minimum, incorporating AIAG PSA?

The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG PSA. Concerns shall be addressed in a timely manner.

Is there a system in place toauthorize reprocessing and is it documented?

The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual. The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible. All reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary plating modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.

Does the Quality Department review, address, and document customer and internal concerns?

The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.

Is there a continual improvement plan applicable to each process defined in the scope of the assessment?

The plater shall define a process for continual improvement for each plating process identified in the scope of the PSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.

Does the Quality Manager or designee authorize the disposition of material from quarantine status?

The Quality Manager or designee is responsible for authorizing and documenting appropriate personnel to disposition quarantine material.

Are there procedures or work instructions available to plating presonnel that define the plating process?

There shall be procedures and work instructions available to plating personnel covering the plating process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.

Page 65: Supplier Evaluation (QVR)Rev6 0112

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory

Needs Immediate Action

Index PageIndex PageCover PageCover Page

1.16

1.17

1.18

1.19

Section 2 - Floor and Material Handling Responsibility

2.1

2.2

2.3

Is management providing employee training for plating?

The organization shall provide employee training for all plating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.

Is there a responsibility matrix to ensure that all key management and supervisory functions are performed by qualified personnel?

The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.

Is there a preventive maintenance program? Is maintenance data being utilized to form a predictive maintenance program?

The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner. Company data, e.g., downtime, quality rejects, first time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Maintenance data shall be collected and analyzed as part of a predictive maintenance program.

Has the plater developed a critical spare part list and are the parts available to minimize production disruptions?

The plater shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.

Does the facility ensure that the data entered in the receiving system matches the information on the customer's shipping documents?

Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. The facility shall have a detailed process in place to resolve receiving discrepancies.

Is product clearly identified and staged throughout the plating process?

Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the plating process. Non-plated, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.

Is lot traceability and integrity maintained throughout all processes?

Out-going lot(s) shall be traceable to the incoming lot(s). The descipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.

Page 66: Supplier Evaluation (QVR)Rev6 0112

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory

Needs Immediate Action

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2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

2.12

2.13

Are procedures adequate to prevent movement of non-conforming product into the production system?

The control of suspect or non-conforming product is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification and tracking of material flow in and out of hold area. Non-conforming hold area shall be clearly designated to maintain segregation of such material.

Is there a system to identify trap points in the entire plating process to reduce risk of mixed parts (inappropriate, unfinished, or improperly plated parts)?

The plater shall have documented procedures to identify and monitor trap points for each process/equipment. Monitoring of potential trap points shall occur for every part changeover.

Are containers free of innappropriate material?

Containers handling customer product shall be free of inappropriate material. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming plating parts or inappropriate material contaminate the finished lot.

Is part loading specified, documented and controlled?

Loading parameters shall be specified, documented and controlled. Examples include parts per rack and load size.

Are operators trained in material handling, containment action and product segregation in the event of an equipment emergency including power failure?

Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment/reaction plans related to all elements of the process. Evidence shall exist showing disposition and traceability of affected product.

Is the handling, storage and packaging adequate to preserve product quality?

The plater's loading/unloading systems, in process handling and shipping process shall be assessed for risk of part damage or other quailty concerns.

Are plant cleanliness, housekeeping and environmental and working conditions conducive to control and improved quality?

Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quailty. The plater should evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for the following items: loose parts on floor; spillage around tanks; overall plant lighting; fumes etc.

Are process control parameters monitored per frequencies specified in Process Tables?

Process control parameters shall be monitored per frequencies specified in Process Tables. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log.

Are out of control/specification parameters reviewed and reacted to?

Are there documented reaction plans to both out of control and out of tolerance process parameters? Is there documented evidence that reaction plans are followed?

Are In-Process / Final Test Frequencies performed as specified in Process Tables?

In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables.

Page 67: Supplier Evaluation (QVR)Rev6 0112

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory

Needs Immediate Action

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2.14Is product test equipment verified?

Test equipment shall be verified/calibrated per applicable customer specific standard or per an applicable consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.

Refer to Process Tables for frequency of checks.

Page 68: Supplier Evaluation (QVR)Rev6 0112

Section 3 - Zinc/ Zinc Alloy Plating Equipment

Assessment

Question Objective Evidence N/A Satisfactory Not Satisfactory

3.1

3.2

3.3

3.4 Are rectifiers maintained?

3.5

3.6

Question Number

Requirements and GuidanceNeeds Immediate

Action

Does plating line have proper process control equipment?

Refer to Process Table F for equipment requirements.

Are process and testing equipment calibrations and/or verification certified, posted, and current?

A system shall be used by the plating facility to track calibration dates of equipment. This system will typically be a computerized tracking system or other notification system. Test equipment shall be verified/calibrated per applicable customer specific standard or consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.

Are barrels, racks, and baskets maintained?

Supplier shall have preventative maintenance system that is documented and implemented.

Supplier shall have preventative maintenance system that is documented and implemented.

For hydrogen embrittlement relief ovens, are temperature uniformity surveys performed yearly?

Uniformity survey must show that ovens were tested both empty and with a dense load. Parts must come up to temperature within one hour of entering oven and meet temperature tolerance specified by customer.

For hydrogen embrittlement relief ovens, are thermocouples checked and/or replaced quarterly?

Supplier shall have preventative maintenance system that is documented and implemented.

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Page 69: Supplier Evaluation (QVR)Rev6 0112

Section 4 - Decorative (Cu, Ni, Cr) Plating Equipment

Question Objective Evidence

Assessment

N/A Satisfactory

4.1

4.2

4.3 Are racks maintained?

4.4 Are rectifiers maintained?

4.5 Are filters maintained?

4.6

4.7

4.8

Question Number

Requirements and Guidance Not Satisfactory

Needs Immediate

Action

Does plating line have proper process control equipment?

Refer to Process Table F for equipment requirements.

Are process and testing equipment calibrations and/or verification certified, posted, and current?

A system shall be used by the plating facility to track calibration dates of equipment. This system will typically be a computerized tracking system or other notification system. Test equipment shall be verified/calibrated per applicable customer specific standard or consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented. Refer to Process Table F, for equipment certification time table

Supplier shall have preventative maintenance system that is documented and implemented.

Supplier shall have preventative maintenance system that is documented and implemented.

Supplier shall have preventative maintenance system that is documented and implemented.

Is all other applicable equipment maintained?

Supplier shall have preventative maintenance system that is documented and implemented.

For all thermocouples/ thermometers are they checked and/or replaced?

Supplier shall have preventative maintenance system that is documented and implemented.

Are the process and equipment alarm checks being tested?

Checks shall be documented. Each alarm shall be reviewed independently for functionality if applicable. Plater shall have a list of alarms relevant to process.

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Page 70: Supplier Evaluation (QVR)Rev6 0112

Section 5 - Job Audit - Finished Product Review

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Material:

Plating Requirements:

Job Audit Question

5.1

N/A

5.2 1.5 N/A

5.3

5.4

5.5 2.1

5.6

5.7

5.8 2.13

5.8.1 Requirement: Plate ThicknessTest Method:Test frequency or quantity:Selection of samples:Specification:

5.8.2

Test Method:Test frequency or quantity:Selection of samples:Specification:

5.8.3

Test Method:Test frequency or quantity:Selection of samples:Specification:

5.8.4 Requirement: Adhesion TestTest Method:Test frequency or quantity:

Question #

RelatedPSA Question #

Customer or Internal Requirement

Job (Shop) Order or Reference Documentation Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

Are contract review, advance quality planning, FMEA, control plans, etc., performed by qualified individuals?

1.21.31.4

1.17

Does the plater have the proper customer specifications for the part?

Is a shop traveler created to meet customer requirements?

1.62.1

Is material identification (part numbers, lot numbers, contract numbers, etc.) maintained throughout the plating process?

2.22.32.4

Is there documented evidence of Receiving Inspection?

Are the Loading / Racking requirements identified?

1.62.72.9

Is the proper procedure or process specification used? Refer to Process Tables for specific parameters. List parameters that were verified in this audit in the spaces provided below.

1.51.62.1

2.112.13

What are the product inspection requirements?

Each part may have one or more requirements determined by the plating specification. Parts must meet each requirement. List each requirement below and validate.

Requirement: Corrosion Resistance

Requirement: Hydrogen Embrittlement Relief (if Applicable)

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Page 71: Supplier Evaluation (QVR)Rev6 0112

Section 5 - Job Audit - Finished Product Review

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Material:

Plating Requirements:

Job Audit QuestionQuestion #

RelatedPSA Question #

Customer or Internal Requirement

Job (Shop) Order or Reference Documentation Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

Cover PageCover Page Index PageIndex Page

Selection of samples:Specification:

5.8.5 Requirement: Alloy (if Applicable)

Test Method:Test frequency or quantity:Selection of samples:Specification:

5.8.6

Test Method:Test frequency or quantity:Selection of samples:Specification:

5.8.7

Test Method:Test frequency or quantity:Selection of samples:Specification:

5.8.8

Test Method:Test frequency or quantity:Selection of samples:Specification:

5.8.9

Test Method:Test frequency or quantity:Selection of samples:Specification:

5.8.10

Test Method:Test frequency or quantity:Selection of samples:Specification:

5.8.11

Test Method:Test frequency or quantity:Selection of samples:Specification:

5.8.12

Test Method:Test frequency or quantity:Selection of samples:Specification:

Operator or Inspector Responsibilities5.9

5.10

Requirement: Torque Tension (if Applicable)

Requirement: Appearance (Decorative)

Requirement: S.T.E.P. (Decorative)

Requirement: Pore Count/Size (Decorative)

Requirement: Ductility by foil (Decorative)

Requirement: Internal Stress (Decorative)

Requirement:Thermal Cycle (Decorative Plastic)

Were appropriate process steps signed off?

1.42.22.3

2.11

Were all inspection steps, as documented in the control plan performed?

1.21.4

Page 72: Supplier Evaluation (QVR)Rev6 0112

Section 5 - Job Audit - Finished Product Review

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Material:

Plating Requirements:

Job Audit QuestionQuestion #

RelatedPSA Question #

Customer or Internal Requirement

Job (Shop) Order or Reference Documentation Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

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5.11

5.12

5.13

5.14 1.17

5.15 2.6

Packaging Requirements5.16 2.9

5.17 2.9

Shipping Requirements5.18 2.3

5.19

Were steps/operations performed that were not documented in the control plan?

1.21.41.6

If additional steps were performed, were they authorized?

1.21.41.6

1.111.17

If the order was certified, did the certification accurately reflect the process performed?

2.112.13

Was the certification signed by an authorized individual?

Are the parts and containers free of foreign objects or contamination?

Are packaging requirements identified?

Are parts packaged to minimize mixed parts (parts packed over height of container)?

Were the parts properly identified?

Were the containers properly labeled?

2.32.9

Page 73: Supplier Evaluation (QVR)Rev6 0112

Assessor(s) shall have the following specific experience to conduct the PLATING SYSTEM ASSESSMENT:

1 Be an experienced quality management system (QMS) internal auditor (for example,ISO/TS 16949-2002, ISO 9001:2000).

2 Assessor shall possess plating knowledge. Evidence shall include a minimum of 5 years experience in plating and surface finishing or a combination of formal chemsitry/chemical engineering education and plating experience totaling a minimum of 5 years.

3 Assessor shall possess knowledge of and be familiar with the application of automotivequality core tools including statistical process control, measurement systems analysis,part approval, failure mode and effects analysis, and advanced quality planning.

Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in item # 1 above.

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Page 74: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control Monitoring

1.0 Metal CleaningType:Size,volume:Proprietary name:Chemical supplier:

A1.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftA1.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/DayA1.3 1.4; 2.11; 2.13 Time Per Tech Data Sheet Per Process SheetA1.4 Agitation Per Tech Data Sheet Per Process SheetA1.5 1.4; 2.11; 2.13 Current/Voltage (As applicable) Automatic 1/ShiftA1.6 Solution Level Automatic or Manual 1/ShiftA1.7 Rinse Process Sheet 1/Shift2.0 Acid

Type:Size,volume:Proprietary name:Chemical supplier:

A2.1 1.4; 2.11; 2.13 Temperature - Optional Automatic 1/ShiftA2.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftA2.3 1.4; 2.11; 2.13 Automatic Continuous

A2.4 Inhibitor Per Tech Data Sheet N/AA2.5 Solution Level Automatic or Manual 1/ShiftA2.6 Rinse Process Sheet 1/Shift3.0 Acid Plating Bath

Type:Size,volume:Proprietary name:Chemical supplier:

A3.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftA3.2 1.4; 2.11; 2.13 Time Automatic 1/ShiftA3.3 1.4; 2.11; 2.13 Current/Voltage Automatic 1/ShiftA3.4 Chloride Concentration Manual 1/DayA3.5 pH Automatic or Manual 1/ShiftA3.6 Plating Test Cell (Hull) Manual 1/DayA3.7 Metal Concentration(s) Automatic or Manual 1/DayA3.8 Buffer (Ammonia / Boric Acid per TDS) Manual 1/DayA3.9 Filtration Continuous 1/Shift

A3.10 Agitation (Rack only - others optional) Continuous 1/ShiftA3.11 Rinse Per Process Sheet 1/Shift

4.0 Alkaline Plating BathType:Size,volume:Proprietary name:

PROCESS TABLE A - Zinc - Zinc Alloy Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

Time (Less than 10 Minutes or Customer Specific)

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Page 75: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control Monitoring

PROCESS TABLE A - Zinc - Zinc Alloy Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

Cover PageCover Page Index PageIndex Page

Chemical supplier:A4.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftA4.2 1.4; 2.11; 2.13 Time Automatic 1/ShiftA4.3 1.4; 2.11; 2.13 Current/Voltage Automatic 1/ShiftA4.4 Caustic Concentration Manual 1/DayA4.5 Plating Test Cell (Hull) Manual 1/DayA4.6 Metal Concentration(s) Automatic or Manual 1/DayA4.7 Filtration Continuous 1/ShiftA4.8 Rinse Per Process Sheet 1/Shift5.0 Hydrogen Embrittlement Relief

3.6 Oven Type:3.6 Oven Temperature:

6.0 PassivatesType:Size,volume:Proprietary name:Chemical supplier:

A6.1 Acid Activation Per Control Plan N/AA6.1.1 - Concentration Automatic or Manual 1/ShiftA6.1.2 1.4; 2.11; 2.13 - Time Automatic or Manual 1/ShiftA6.2 Passivate Per Control Plan N/A

A6.2.1 - Concentration Automatic or Manual 1/ShiftA6.2.2 1.4; 2.11; 2.13 - Temperature Automatic or Manual 1/ShiftA6.2.3 1.4; 2.11; 2.13 - Time Automatic or Manual 1/ShiftA6.2.4 - pH Automatic or Manual 1/ShiftA6.2.5 - Agitation Automatic or Manual 1/ShiftA6.2.6 - Contamination (e.g. Fe, Zn) Per Process Sheet 1/weekA6.3 Rinse Per Process Sheet 1/ShiftA6.4 Dry Per Tech Data Sheet Per Process Sheet

7.0

A7.1 Concentration Automatic or Manual

A7.2 1.4; 2.11; 2.13 Solution Temperature Automatic

A7.3 1.4; 2.11; 2.13 Time Automatic or Manual

A7.4 pH Automatic or Manual

A7.5 Drying Temperature Automatic

A7.6 Spin Speed Automatic

Supplemental Treatments - Sealers and Torque Tension Modifiers

Per Control Plan and TDS

Per Control Plan and TDS

Per Control Plan and TDS

Per Control Plan and TDS

Per Control Plan and TDS

Per Control Plan and TDS

Page 76: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control Monitoring

PROCESS TABLE A - Zinc - Zinc Alloy Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

Cover PageCover Page Index PageIndex Page

A7.7 Agitation Automatic or Manual Per Control Plan and TDS

Page 77: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control Monitoring

1.0 Polishing and BuffingB1.1 ManualB1.2 AutomaticB1.3 SteelB1.4 Stainless SteelB1.5 AluminumB1.6 Zinc diecast2.0 Metal Cleaning

Type:Size,volume:Proprietary name:Chemical supplier:

B2.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftB2.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftB2.3 1.4; 2.11; 2.13 Time Per TDS Per process sheetB2.4 Agitation - Optional Per TDS Per process sheetB2.5 4.4 Current/Voltage (As applicable) Automatic 1/ShiftB2.6 Solution Level Automatic or Manual 1/ShiftB2.7 Rinse Process Sheet 1/Shift3.0 Pretreatment

B3.1 Strike (As applicable) N/A N/AB3.1.1 1.4; 2.11; 2.13 - Temperature Automatic 1/ShiftB3.1.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/ShiftB3.1.3 1.4; 2.11; 2.13 - Time Automatic Per process sheetB3.1.4 - Agitation - Optional Per TDS Per process sheetB3.1.5 4.4 - Current/Voltage (if applicable) Automatic 1/ShiftB3.1.6 - Solution Level Automatic or Manual 1/ShiftB3.1.7 - Rinse Process Sheet 1/ShiftB3.2 Zincate (Aluminum Only) N/A N/A

B3.2.1 1.4; 2.11; 2.13 - Temperature Automatic 1/ShiftB3.2.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/ShiftB3.2.3 1.4; 2.11; 2.13 - Time Automatic Per process sheetB3.2.4 - Agitation - Optional Per TDS Per process sheetB3.2.5 - Solution Level Automatic or Manual 1/ShiftB3.2.6 - Dump Schedule Per TDS Per process sheetB3.2.7 Rinse Process Sheet 1/Shift

4.0 AcidType:Size,volume:Proprietary name:Chemical supplier:

B4.1 1.4; 2.11; 2.13 Temperature - Optional Automatic 1/ShiftB4.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftB4.3 1.4; 2.11; 2.13 Time (Per Specification) Automatic Continuous

PROCESS TABLE B - Surface Conditioning of Metals for Decorative Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

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Page 78: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control Monitoring

PROCESS TABLE B - Surface Conditioning of Metals for Decorative Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

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B4.4 Solution Level Automatic or Manual 1/ShiftB4.5 Rinse Process Sheet 1/Shift

(Proceed to Process Table D - Decorative Plating)

Page 79: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control Monitoring

1.0 Cleaning and Pre-Etch (If Applicable)Type:Size,volume:Proprietary name:Chemical supplier:

C1.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC1.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC1.3 1.4; 2.11; 2.13 Time Automatic Per process sheetC1.4 Agitation Per TDS Per process sheetC1.5 Solution Level Automatic or Manual 1/ShiftC1.6 Rinse Process Sheet 1/Shift2.0 Etch

Type:Size,volume:Proprietary name:Chemical supplier:

C2.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC2.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC2.3 1.4; 2.11; 2.13 Time Automatic Per process sheetC2.4 Agitation Per TDS Per process sheetC2.5 Solution Level Automatic or Manual 1/ShiftC2.6 Rinse Process Sheet 1/Shift3.0 Neutralizer

Type:Size,volume:Proprietary name:Chemical supplier:

C3.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC3.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC3.3 1.4; 2.11; 2.13 Time Automatic Per process sheetC3.4 Agitation Per TDS Per process sheetC3.5 Solution Level Automatic or Manual 1/ShiftC3.6 Rinse Process Sheet 1/Shift4.0 Activator

Type:Size,volume:Proprietary name:Chemical supplier:

C4.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC4.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC4.3 1.4; 2.11; 2.13 Time Automatic Per process sheet

PROCESS TABLE C - Surface Conditioning of ABS & PCABS Plastic for Decorative Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

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Page 80: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control Monitoring

PROCESS TABLE C - Surface Conditioning of ABS & PCABS Plastic for Decorative Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

Cover PageCover Page Index PageIndex Page

C4.4 Agitation Per TDS Per process sheetC4.5 Solution Level Automatic or Manual 1/ShiftC4.6 Rinse Process Sheet 1/Shift5.0 Accelerator

Type:Size,volume:Proprietary name:Chemical supplier:

C5.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC5.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC5.3 1.4; 2.11; 2.13 Time Automatic Per process sheetC5.4 Agitation Per TDS Per process sheetC5.5 Solution Level Automatic or Manual 1/ShiftC5.6 Rinse Process Sheet 1/Shift6.0 Electroless Plating

Type:Size,volume:Proprietary name:Chemical supplier:

C6.1 1.4; 2.11; 2.13 - Temperature Automatic 1/ShiftC6.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/ShiftC6.3 1.4; 2.11; 2.13 - Time Automatic Per process sheetC6.4 - Agitation Per TDS Per process sheetC6.5 - Solution Level Automatic or Manual 1/ShiftC6.6 - Rinse Process Sheet 1/Shift7.0 Electrolytic Plating - Strike

Type:Size,volume:Proprietary name:Chemical supplier:

C7.1 1.4; 2.11; 2.13 - Temperature Automatic 1/ShiftC7.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/DayC7.3 4.1, 4.4 - Current Automatic 1/ShiftC7.4 1.4; 2.11; 2.13 - Time Automatic 1/ShiftC7.5 - Agitation Per TDS 1/ShiftC7.6 - Solution Level Automatic or Manual 1/ShiftC7.7 - Rinse Process Sheet 1/Shift

Page 81: Supplier Evaluation (QVR)Rev6 0112

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Page 82: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control Monitoring

1.0 Acid Copper (as applicable)Type:Size,volume:Proprietary name:Chemical supplier:

D1.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD1.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD1.3 1.4; 2.11; 2.13 Time Automatic Per process sheetD1.4 Agitation Per TDS Per process sheetD1.5 4.1, 4.4 Current/Voltage Per Process Sheet Per JobD1.6 Solution Level Automatic or Manual 1/ShiftD1.7 Rinse Per Process Sheet 1/ShiftD1.8 Filtration Continuous 1/ShiftD1.9 Post Clean Per Process Sheet 1/Day2.0 Semi-Bright Nickel

Type:Size,volume:Proprietary name:Chemical supplier:

D2.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD2.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD2.3 1.4; 2.11; 2.13 Time Automatic Per process sheetD2.4 Agitation Per TDS Per process sheetD2.5 4.1, 4.4 Current/Voltage Per Process Sheet Per JobD2.6 Solution Level Automatic or Manual 1/ShiftD2.7 4.2 pH Automatic 1/ShiftD2.8 4.2 Internal stress test Manual 1/MonthD2.9 4.2 Ductility test Manual 1/Month

D2.10 4.2 Sulfur Concentration (as deposited) Manual 1/MonthD2.11 Filtration Continuous 1/Shift

3.0 High Activity Nickel (as applicable)Type:Size,volume:Proprietary name:Chemical supplier:

D3.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD3.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD3.3 1.4; 2.11; 2.13 Time Automatic Per process sheetD3.4 Agitation Per TDS Per process sheetD3.5 4.1, 4.4 Current/Voltage Per Process Sheet Per JobD3.6 Solution Level Automatic or Manual 1/ShiftD3.7 pH Automatic 1/ShiftD3.8 Filtration Continuous Per process sheet4.0 Bright Nickel

Type:

PROCESS TABLE D - Decorative Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

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Page 83: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control Monitoring

PROCESS TABLE D - Decorative Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

Index PageIndex PageCover PageCover Page

Size,volume:Proprietary name:Chemical supplier:

D4.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD4.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD4.3 1.4; 2.11; 2.13 Time Automatic Per process sheetD4.4 Agitation Per TDS Per process sheetD4.5 4.1,4.4 Current/Voltage Per Process Sheet Per JobD4.6 Solution Level Automatic or Manual 1/ShiftD4.7 pH Automatic 1/ShiftD4.8 Internal stress test Manual 1/MonthD4.9 Ductility test Manual 1/Month

D4.10 Filtration Continuous 1/Shift5.0 Microporous Nickel

Type:Size,volume:Proprietary name:Chemical supplier:

D5.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD5.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD5.3 1.4; 2.11; 2.13 Time Automatic Per Process SheetD5.4 Agitation Per TDS Per Process SheetD5.5 4.1,4.4 Current/Voltage Per Process Sheet Per JobD5.6 Solution Level Automatic or Manual 1/ShiftD5.7 4.2 pH Automatic 1/ShiftD5.8 Rinse Per Process Sheet 1/ShiftD5.9 4.2 STEP Test (of final product) Manual 1/Day6.0 Chromium

Type:Size,volume:Proprietary name:Chemical supplier:

D6.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD6.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 2/ShiftD6.3 1.4; 2.11; 2.13 Time Automatic Per Process SheetD6.4 Agitation (if applicable) Per TDS Per Process SheetD6.5 4.1,4.4 Current/Voltage Per Process Sheet Per JobD6.6 Solution Level Automatic or Manual 1/ShiftD6.7 Rinse Per Process Sheet 1/ShiftD6.8 4.2 Pore Count and Pore Size Manual 1/Day

Page 84: Supplier Evaluation (QVR)Rev6 0112

ITEM #Category/Process Steps Control Monitoring

1.0 Metal Cleaning (Off Line)

E1.1 1.4; 2.11; 2.13 Temperature Automatic 1/Shift

E1.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/Shift

E1.3 1.4; 2.11; 2.13 Time Automatic or Manual Per Process Sheet

E1.4 Agitation Per TDS Per Process Sheet

E1.5 Solution Level Automatic or Manual 1/Shift

E1.6 Rinse Per Process Sheet 1/Shift

2.0 Mechanical Plating

E2.1 Load Size (e.g. weight, area, volume) Per Process Sheet per load

E2.2 Water Volume Per Process Sheet per load

E2.3 1.4; 2.11; 2.13 Temperature Per Process Sheet per load

E2.4.1 Media Mix (Ratio) - Sieve Testing Per Process Sheet 1 x per week

E2.4.2 Media (Load Volume) Per Process Sheet per load

E2.4.3 Per Process Sheet 1 x per week

E2.5.1 Surface Conditioner (Volume or weight) Per Process Sheet per load

E2.5.2 Surface Conditioner (Time) Per Process Sheet per load

E2.6.1 Per Process Sheet per load

E2.6.2 Surface preparation (Time) Per Process Sheet per load

E2.7.1 Promoter(s) (Volume) Per Process Sheet per load

E2.7.2 Promoter (Time) Per Process Sheet per load

E2.8.1 Zinc Flash (Weight or volume) Per Process Sheet per load

E2.8.2 Zinc Flash (Time) Per Process Sheet per load

E2.9.1 Metal Addition (Weight or volume) Per Process Sheet per load

E2.9.2 Metal Addition (Number of Adds) Per Process Sheet per load

E2.10 3.2 pH adjustments (Dependent on Adds) Per Process Sheet as needed

E2.11 Metal (Thickness) Per Process Sheet per load

E2.12 Water Polish (time) Per Process Sheet per load

PROCESS TABLE E - Mechanical Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

Media (Cleanliness - To Avoid Contamination)

Surface preparation (Volume or weight) - Cu Flash

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Page 85: Supplier Evaluation (QVR)Rev6 0112

ITEM #Category/Process Steps Control Monitoring

PROCESS TABLE E - Mechanical Plating

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

Cover PageCover Page Index PageIndex Page

E2.13 Part/Media Separation Per Process Sheet per load

3.0 Passivates

E3.1 Acid Activation per Control Plan

E3.1.1 1.4; 2.11; 2.13 - Concentration Per Process Sheet 1/Shift

E3.1.2 1.4; 2.11; 2.13 - Time Per Process Sheet 1/Shift

E3.2 Passivate

E3.2.1 1.4; 2.11; 2.13 - Concentration Per Process Sheet 1/Shift

E3.2.2 1.4; 2.11; 2.13 - Temperature Per Process Sheet 1/Shift

E3.2.3 1.4; 2.11; 2.13 - Time Per Process Sheet 1/Shift

E3.2.4 3.2 - pH Per Process Sheet 1/Shift

E3.2.5 - Agitation Per Process Sheet 1/Shift

E3.2.6 - Contamination (e.g. Fe, Zn) Per Process Sheet 1/week

E3.3 Rinse Per Process Sheet 1/Shift

E3.4 Dry Per Process Sheet Per Process Sheet

4.0

E4.1.1 1.4; 2.11; 2.13 - Concentration Automatic or Manual

E4.1.2 1.4; 2.11; 2.13 - Solution Temperature Automatic or Manual

E4.1.3 1.4; 2.11; 2.13 - Time Automatic or Manual

E4.1.4 3.2 - pH Automatic or Manual

E4.1.5 - Drying Temperature Automatic

E4.1.6 - Spin Speed Automatic

E4.1.7

- Agitation Automatic or Manual

Supplemental Treatments - Sealers and Torque Tension Modifiers

Per Control Plan and TDS

Per Control Plan and TDS

Per Control Plan and TDS

Per Control Plan and TDS

Per Control Plan and TDS

Per Control Plan and TDS

Per Control Plan and TDS

Page 86: Supplier Evaluation (QVR)Rev6 0112

LABORATORY EQUIPMENTITEM # EQUIPMENT TYPE

F1 2.14; 3.1; 4.1; 4.2 X X pH Meter/Probe Daily YearlyF1.2 2.14; 3.1; 4.1; 4.2 X X Wet Analysis N/A N/AF1.3 2.14; 3.1; 4.1; 4.2 X X Atomic Absorption (Optional)

MINIMUM REQUIRED TESTING CAPABILITYF1.4 3 X Salt Spray Cabinet N/A YearlyF1.5 3.2 & 4.2 X X Thickness Tester Daily YearlyF1.6 2.14; 3.1; 4.1; 4.2 X STEP N/A YearlyF1.7 2.14; 3.1; 4.1; 4.2 X CASS N/A YearlyF1.8 2.14; 3.1; 4.1; 4.2 X Microscope N/A YearlyF1.9 2.14; 3.1; 4.1; 4.2 X Freezer (POP only) N/A YearlyF1.10 2.14; 3.1; 4.1; 4.2 X Lab Oven (POP only) N/A YearlyF1.11 2.14; 3.1; 4.1; 4.2 X Stress (External Testing Acc.) N/A Yearly

F1.12 2.14; 3.1; 4.1; 4.2 X Daily Yearly

F2 2.14; 3.1; 4.1; 4.2 X N/A Yearly

F2.1 2.14; 3.1; 4.1; 4.2 X Pore Count/Active Sites N/A N/AF2.2 2.14; 3.1; 4.1; 4.2 X Pull Tester N/A YearlyF2.3 3.2 & 4.2 X X Lab Rectifier N/A Yearly

PROCESS EQUIPMENTITEM EQUIPMENT TYPE

F3 X X

3.3 & 4.3 X X Rack Rack Size

3.3 X BarrelHorizontalOblique

Barrel Size -volume

-dimensionsF3.1 X X Hoist

Manual Automatic Rack SizeBarrel Size

F3.2 3.4 & 4.4 X X Rectifier TypeWater cooled

Air cooled

PROCESS TABLE F - EQUIPMENT

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. The auditor shall verify plater is conforming to customer requirements.

Related PSA Question #

Zinc/Zinc Alloy

Decorative Plating

Verification Frequency

Calibration Frequency

Sulfur by Foil (External Testing Acc.)

Ductility (External Testing Acc.)

PSA Clause Number

Zinc & Zinc Alloy

Plating

Decorative Plating

Verification Frequency

Calibration Frequency

Machine - Return type automatic

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Page 87: Supplier Evaluation (QVR)Rev6 0112

PROCESS TABLE F - EQUIPMENT

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. The auditor shall verify plater is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Amperage controlled ITEM

EQUIPMENT TYPE

Voltage controlledF3.3 X X Filters

Pre-packCartridge

OtherF3.4 3.5 X Oven type

ContiniousBatch

3.5 X Chart recorder3.6 X Themocouples

number3.3 X Basket type

Expanded metalPerforated

SolidSize

F3.5 X X ControllersAutomatic feeders

TimersTemperature

VolumeF3.6 X X Agitation type

Air Cathode rod

F3.7 X X Water sourceTapRO

Deionized

PSA Clause Number

Zinc & Zinc Alloy

Plating

Decorative Plating

Verification Frequency

Calibration Frequency

Page 88: Supplier Evaluation (QVR)Rev6 0112

CQI-12 COATING SYSTEM ASSESSMENTInstructions for completing the Cover Sheet

1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and CoatingSpecialist) or different management system, then these locations shall be considered as separate facilities.

2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.

3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.

4 Fax number: The fax number of the facility.

5 Number of Coating Employees at this Facility: The number of employees, salaried and hourly, associated with the coating operation at this facility.

6 Captive Coater (Y/N): Enter "Y" if this facility coats components for their own company. Enter"N" if the company does not coat any components for their own company.

7 Commercial Coater (Y/N): Enter "Y" if this facility coats components for companies other thantheir own company. Enter "N" if this facility does not coat any components for other companies.

8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.

9 Date of Previous Assessment: List the date of the previous CQI-12 Special Process: CoatingSystem Assessment of this facility.

10 Type(s) of Coating at this Facility: Place a checkmark to designate the coating process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the CoatingSystem Assessment.

11 Current Quality Certification(s): the coater shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.

12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the coater shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.

13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the coater's organization.

14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).

15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.

16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.

17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.

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Page 89: Supplier Evaluation (QVR)Rev6 0112

Special Process: Coating System Assessment

Facility Name:Address:

Phone Number: Type(s) of Coating Processes at this Facility:Fax Number: Process Table A

Aqueous CleaningNumber of Coating Employees at this Facility: Process Table B

Mechanical CleaningCaptive Coater (Y/N): Process Table CCommercial Coater (Y/N): Phosphating

Process Table DDate of Assessment: Powder Coating

Process Table E Date of Previous Assessment: Electrocoat

Process Table FSprayProcess Table GDip/SpinProcess Table HAutophoreticProcess Table IConvective CureProcess Table JEquipment

Current Quality Certification(s):

Date of Re-assessment (if necessary):

Personnel Contacted:Name: Title: Phone: Email:

0 00 00 00 0

Auditors/Assesors:Name: Company: Phone: Email:

0000

Number of "Not Satisfactory" Findings:

Number of "Needs Immediate Action" Findings:

Number of "Fail" Findings in the Job Audit(s):

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Page 90: Supplier Evaluation (QVR)Rev6 0112

Special Process: Coating System Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A Satisfactory

Section 1 - Management Responsibility and Quality Planning

1.1

1.2

1.3

1.4

Question Number

Not Satisfactory

Needs Immediate

Action

Is there a dedicated and qualified coating person on-site?

To ensure readily available expertise, there shall be a dedicated and qualified coating person on the site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including chemical and coating knowledge. The qualifications shall include a minimum of 5 years experience in coating operation or a combination of a minimum of 5 years of formal chemical education and coating experience.

Does the coater perform advanced quality planning?

The organization shall incorporate a documented advanced quality planning procedure. A feasibility study shall be performed and internally approved for each new part or process. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The coater shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.

Are the coater's FMEA's up to date and reflecting current processing?

The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEAs are updated to reflect current part quality status. The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key coating process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.

Are finish process control plans up to date and reflecting current processing?

The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls. The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key coating process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEAs. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables.

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Page 91: Supplier Evaluation (QVR)Rev6 0112

Special Process: Coating System Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory

Needs Immediate

Action

Index PageIndex PageCover PageCover Page

1.5

1.6

1.7

1.8

1.9

Are all coating related and referenced specifications current and available? For example: SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler.

To ensure all customer requirements are both understood and satisfied, the organization shall have all related coating and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards and specifications and changes based on customer-required schedule. This process shall be executed as soon as possible and shall not exceed two weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks.

Is there a written process specification for all active processes?

The coater shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, rectifier settings, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control. All active processes should have a written process specification. These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.

Has a valid product capability study been performed initially and after process change?

To demonstrate each process is capable of yielding acceptable product, the organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, and after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all coating processes per line as defined in scope of work and in accordance with customer requirements. Capability study techniques shall be appropriate for the coating product characteristics, e.g., coating thickness, corrosion resistance, etc.. Any specific customer requirements shall be met. In the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to be followed in case capability indices fall outside customer requirements or established ranges.

Does the coater collect and analyze data over time, and react to this data?

The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time. Methods of analysis shall include ongoing trend or historical data analysis of special product or process parameters. The organization shall determine which parameters to include in such analysis.

Are internal assessments being completed on an annual basis, at a minimum, incorporating AIAG CSA?

The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG CSA. Concerns shall be addressed in a timely manner.

Page 92: Supplier Evaluation (QVR)Rev6 0112

Special Process: Coating System Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory

Needs Immediate

Action

Index PageIndex PageCover PageCover Page

1.10

1.11

1.12

1.13

1.14

1.15

1.16

Is there a system in place toauthorize reprocessing and is it documented?

The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual. The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible. All reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary coating modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.

Does the Quality Department review, address, and document customer and internal concerns?

The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.

Is there a continual improvement plan applicable to each process defined in the scope of the assessment?

The coater shall define a process for continual improvement for each coating process identified in the scope of the CSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.

Does the Quality Manager or designee authorize the disposition of material from quarantine status?

The Quality Manager or designee is responsible for authorizing and documenting appropriate personnel to disposition quarantine material.

Are there procedures or work instructions available to coating personnel that define the coating process?

There shall be procedures or work instructions available to coating personnel covering the coating process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.

Is management providing employee training for coating?

The organization shall provide employee training for all coating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.

Is there a responsibility matrix to ensure that all key management and supervisory functions are performed by qualified personnel?

The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.

Page 93: Supplier Evaluation (QVR)Rev6 0112

Special Process: Coating System Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory

Needs Immediate

Action

Index PageIndex PageCover PageCover Page

1.17

1.18

Section 2 - Floor and Material Handling Responsibility

2.1

2.2

2.3

2.4

2.5

2.6

2.7

Is there a preventive maintenance program? Is maintenance data being utilized to form a predictive maintenance program?

The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner. Company data, e.g., downtime, quality rejects, first time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Maintenance data shall be collected and analyzed as part of a predictive maintenance program.

Has the coater developed a critical spare part list, and are the parts available to minimize production disruptions?

The coater shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.

Does the facility ensure that the data entered in the receiving system matches the information on the customer's shipping documents?

Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. The facility shall have a detailed process in place to resolve receiving discrepancies.

Is product clearly identified and staged throughout the coating process?

Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the coating process. Non-coated, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.

Is lot traceability and integrity maintained throughout all processes?

Out-going lot(s) shall be traceable to the incoming lot(s).The descipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.

Are procedures adequate to prevent movement of non-conforming product into the production system?

The control of suspect or non-conforming product is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification and tracking of material flow in and out of hold area. Non-conforming hold area shall be clearly designated to maintain segregation of such material.

Is there a system to identify trap points in the entire process to reduce risk of mixed parts (inappropriate, unfinished or improperly coated parts)?

The coater shall have documented procedures to identify and monitor trap points for each process/equipment. Monitoring of potential trap points shall occur for every part changeover.

Are containers free of inappropriate material?

Containers handling customer product shall be free of inappropriate material. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming coated parts or inappropriate material contaminate the finished lot.

Is part loading specified, documented and controlled?

Loading parameters shall be specified, documented and controlled. Examples include parts per rack and load size.

Refer to Process Tables for frequency of checks.

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Special Process: Coating System Assessment (General Facility Overview)

Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory

Needs Immediate

Action

Index PageIndex PageCover PageCover Page

2.8

2.9

2.10

2.11

2.12

2.13

2.14

Are operators trained in material handling, containment action and product segregation in the event of an equipment emergency including power failure?

Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment/reaction plans related to all elements of the process. Evidence shall exist showing disposition and traceability of affected product.

Is the handling, storage and packaging adequate to preserve product quality?

The coater's loading/unloading systems, in-process handling and shipping process shall be assessed for risk of part damage or other quailty concerns.

Are plant cleanliness, housekeeping, environmental and working conditions conducive to control and improved quality?

Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality. The coater should evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for the following items: loose parts on floor; spillage around tanks; overall plant lighting; fumes etc.

Are process control parameters monitored per frequencies specified in Process Tables?

Process control parameters shall be monitored per frequencies specified in Process Tables. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log.

Are out of control/specification parameters reviewed and reacted to?

There are documented reaction plans to both out of control and out of tolerance process parameters. There is documented evidence that reaction plans are followed.

Are In-Process / Final Test Frequencies performed as specified in Process Tables?

In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables

Is product test equipment verified?

Test equipment shall be verified/calibrated per applicable customer specific standard or per an applicable consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.

Refer to Process Tables for frequency of checks.

Page 95: Supplier Evaluation (QVR)Rev6 0112

Section 3 - Job Audit - Finished Product Review

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Coating Requirements:

Question # Job Audit Question

3.1 N/A

3.2 1.5

N/A

3.3

3.4

3.5 2.1

3.6

3.7

3.8

3.8.1 Requirement: Coating ThicknessTest Method:Test frequency or quantity:Selection of samples:Specification:

3.8.2

Test Method(s):Test frequency or quantity:Selection of samples:Specification:

3.8.3

Test Method:Test frequency or quantity:Selection of samples:Specification:

3.8.4 Requirement: AdhesionTest Method(s):Test frequency or quantity:Selection of samples:Specification:

3.8.5 Requirement: CureTest Method:

RelatedCSA Question #

Customer or Internal Requirement

Job (Shop) Order or Reference Documentation

Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

Is contract review and advanced quality planning, FMEA, control plans, etc., performed by qualified individuals?

1.11.21.31.41.6

Does the Coater have the proper customer specifications for the part?

Is a shop traveler created to meet customer requirements?

1.62.1

Is material identification (part numbers, lot numbers, contract numbers, etc.) maintained throughout the coating process?

2.22.32.4

Is there documented evidence of Receiving Inspection?

Are the Loading / Racking requirements identified?

1.62.72.9

Is the proper procedure or process specification used? Refer to Process Tables for specific parameters. List parameters that were verified in this audit in the spaces provided below.

1.51.62.1

2.112.13

What are the product inspection requirements?

1.5 2.13

2.14

Each part may have one or more requirements determined by the coating specification. Parts must meet each requirement. List each requirement below and validate.

(Listed below are some examples)

Requirement: Corrosion Resistance (if applicable).

Requirement: Hydrogen Embrittlement Relief (if applicable)

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Page 96: Supplier Evaluation (QVR)Rev6 0112

Section 3 - Job Audit - Finished Product Review

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Coating Requirements:

Question # Job Audit QuestionRelated

CSA Question #Customer or Internal

Requirement

Job (Shop) Order or Reference Documentation

Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

Index PageIndex PageCover PageCover Page

Test frequency or quantity:Selection of samples:Specification

3.8.6

Test Method:Test frequency or quantity:Selection of samples:Specification:

3.8.7

Test Method:Test frequency or quantity:Selection of samples:Specification

3.8.8

Test Method:Test frequency or quantity:Selection of samples:Specification:

3.8.9

Test Method:Test frequency or quantity:Selection of samples:Specification:

3.8.10 Requirement: Customer SpecificTest Method(s):Test frequency or quantity:Selection of samples:Specification:

Operator or Inspector Responsibilities

3.9

3.10

3.11

3.12

3.13

3.14

3.15

3.16 2.6

Packaging Requirements

Requirement: Torque Tension (if applicable)

Requirement: Appearance (Decorative)

Requirement: Dimensional (if applicable)

Requirement: Color and Gloss (Decorative)

Were appropriate process steps signed off?

1.41.62.22.3

2.11

Were all inspection steps, as documented in the control plan performed?

1.21.4

Were steps/operations performed that were not documented in the control plan?

1.21.41.6

If additional steps were performed, were they authorized?

1.21.41.6

1.101.16

Does the governing specification allow reprocessing or rework?

1.51.10

If the order was certified, did the certification accurately reflect the process performed?

2.112.13

Was the certification signed by an authorized individual?

1.16

Are the parts and containers free of inappropriate objects or contamination?

Page 97: Supplier Evaluation (QVR)Rev6 0112

Section 3 - Job Audit - Finished Product Review

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Coating Requirements:

Question # Job Audit QuestionRelated

CSA Question #Customer or Internal

Requirement

Job (Shop) Order or Reference Documentation

Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

Index PageIndex PageCover PageCover Page

3.17

3.18

Shipping Requirements

3.19

3.20

Are packaging requirements identified?

2.6 2.7

2.9

Are parts packaged to minimize mixed parts (for example, parts packed over height of container)?

2.6 2.7

2.9

Were the parts properly identified? 2.32.9

Were the containers properly labeled?

2.32.9

Page 98: Supplier Evaluation (QVR)Rev6 0112

Assessor(s) shall have the following specific experience to conduct the COATING SYSTEM ASSESSMENT:

1 Be an experienced quality management system (QMS) internal auditor (for example,ISO/TS 16949-2002, ISO 9001:2000).

2 Assessor shall possess coating knowledge. Evidence shall include a minimum of 5years experience in coating or a combination of formal chemical education and coating experience totaling a minimum of 5 years.

3 Assessor shall possess knowledge of and be familiar with the application of automotivequality core tools including statistical process control, measurement systems analysis,part approval, failure mode and effects analysis, and advanced quality planning.

Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in item # 1 above.

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Page 99: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

1.0

A1.1 1.4 Per Control Plan Per lot

2.0 Cleaning Bath(s)

A2.1 2.11

A2.2 Pressure/Agitation Automatic/Manual

A2.3 Temperature Automatic/Manual

A2.4 Time Automatic/Manual

A2.5 Chemical Concentration Automatic/Manual

A2.6 Impurity Content (e.g. acid split) Manual

A2.7 2.11 There is a dump schedule for cleaning baths. Manual Per Control Plan/Log Sheet

3.0 Rinse Bath(s)

A3.1 2.11

A3.2 Pressure/Agitation Automatic/Manual

A3.3 Temperature Automatic/Manual

PROCESS TABLE A - Pretreatment (Aqueous)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

AQUEOUS CLEANING PROCESS (Alkaline or Acid)

There shall be an incoming part assessment procedure with criteria.

The following checks shall be performed during production:

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 1.6 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 1.6 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

The following checks shall be performed during production:

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

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Page 100: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE A - Pretreatment (Aqueous)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Cover PageCover Page Index PageIndex Page

A3.4 Time Automatic/Manual

A3.5 Impurity Concentration Manual

A3.6 Overflow Rate Automatic/Manual

A3.7 2.11 There is a dump schedule for rinses. Manual Per Control Plan/Log Sheet

A3.8 Manual

A3.9 Manual

A3.10 Automatic/Manual

1.4 1.6 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

There is a visual inspection (e.g. water break) after each post cleaning rinse bath where possible. (not applicable for bulk)

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

There is a final rinse. It shall be monitored for presence of bacteria. (for plastic substrate)

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

For Metals -- Corrosion inhibitor concentration is checked. (If applicable)

Per Control Plan/Log Sheet (1/shift minimum)

Page 101: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

1.0 ABRASIVE BLAST PROCESS

B1.1 1.4 Per Control Plan Per lot

B1.2 2.11

B1.3 Abrasive media flow Automatic/Manual

B1.4 Nozzle air pressure Automatic/Manual

B1.5 Dwell time Automatic/Manual

B1.6 Dust collector efficiency/air flow Automatic

B1.7 Working mix Automatic/Manual

PROCESS TABLE B - Pretreatment (Mechanical)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA

Question #

There shall be an incoming part assessment procedure with criteria.

The following checks shall be performed during production:

1.4 1.6 2.11

2.12

Per Control Plan/Log Sheet (1/shift

minimum)

1.4 1.6 2.11

2.12

Per Control Plan/Log Sheet (1/shift

minimum)

1.4 1.6 2.11

2.12

Per Control Plan/Log Sheet (1/shift

minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (2/shift

minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift

minimum)

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Page 102: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE B - Pretreatment (Mechanical)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA

Question #

Index PageIndex PageCover PageCover Page

B1.8 Surface cleanliness is checked after process. Manual

B1.9 Manual Per lot

1.4 2.11

Per Control Plan/Log Sheet (1/shift

minimum)

1.4 2.11

2.13

Surface profile is checked after process (if applicable).

Page 103: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

1.0 Conversion Coating

C1.1 1.4 Per Control Plan Per lot

2.0 Rinse Conditioner (If Applicable)

C2.1 2.11

C2.2 Pressure/Agitation Automatic/Manual

C2.3 Time Automatic/Manual

C2.4 Chemical Concentration Automatic/Manual

C2.5 2.11 Manual

PROCESS TABLE C - Pretreatment (Phosphating)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

There shall be an incoming part assessment procedure with criteria.

The following checks shall be performed during production:

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.6

2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

There is a dump schedule for rinse conditioner.

Per Chemical Manufacturer's Guideline

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Page 104: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE C - Pretreatment (Phosphating)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

3.0 Conversion Coating Bath

C3.1 2.11

C3.2 Pressure/Agitation Automatic/Manual

C3.3 Temperature Automatic/Manual

C3.4 Time Automatic/Manual

C3.5 Automatic/Manual

C3.6 Automatic/Manual

C3.7 Coating Weight Manual

The following checks shall be performed during production:

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.6

2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Chemical Concentration (Free Acid, Total Acid, Iron Content, pH, Accelerator Amount as Applicable)

Per Control Plan/Log Sheet (2/shift minimum)

1.4 2.11

2.12

Fluoride Ion Concentration (if aluminum is being coated)

Per Control Plan/Log Sheet (2/shift minimum)

1.41.6

2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

Page 105: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE C - Pretreatment (Phosphating)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

C3.8 Crystal Size (If applicable) Manual

4.0 Rinse After Phosphate

C4.1 2.11

C4.2 Manual

C4.3 Pressure/Agitation Automatic/Manual

C4.4 Time Automatic/Manual

C4.5 2.11 There is a dump schedule for rinses Manual

5.0 Seal Rinse

1.4 2.11

2.12

Per customer requirement

The following checks shall be performed during production:

1.4 2.11

2.12

Impurity Concentration (e.g. Titration, Conductivity)

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.6

2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

Per Chemical Manufacturer's Guideline

Page 106: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE C - Pretreatment (Phosphating)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

C5.1 2.11

C5.2 Pressure/Agitation Automatic/Manual

C5.3 Time Automatic/Manual

C5.4 Chemical Concentration Automatic/Manual

C5.5 Temperature (If applicable) Automatic/Manual

C5.6 2.11 There is a dump schedule for seal rinse. Manual

6.0 Dry-Off (If Applicable)

C6.1 Automatic

The following checks shall be performed during production:

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.6

2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

Per Chemical Manufacturer's Guideline

1.4 2.11

2.12

Air temperature is monitored and controlled.

Per Control Plan/Log Sheet (1/shift minimum)

Page 107: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE C - Pretreatment (Phosphating)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

C6.2 Visual Each Lot1.4 2.11

There is a procedure to ensure dryness of parts prior to susequent coating.

Page 108: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

1.0 Powder Paint Application

D1.1 Manual

2.0 Powder Booth and Equipment

D2.1 The temperature of parts entering the coating booth is monitored. Automatic/Manual

D2.2 Automatic

D2.3 Automatic/Manual

D2.4 The air dryer and filter are on main compressed air line. Automatic/Manual

D2.5 The booth temperature and humidity are checked. Manual

D2.6 The air balance in the powder booth is checked. Manual

D2.7 The rotary seive is clean and operational. Automatic/Manual

D2.8 The powder flow on seive is monitored. Automatic/Manual

D2.9 The vent assist air pressure is checked. Manual

D2.10 The vent on feed hopper is checked. Manual

D2.11 The reclaim seive is operating properly. Manual

D2.12 All guns are operational and in good repair. Manual

D2.13 Manual Per PM schedule

D2.14 Manual

PROCESS TABLE D - Powder

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

1.4 2.11

Parts are checked exiting dry-off oven for cleanliness and trapped water, prior to entering powder booth.

Per Control Plan/Log Sheet (1 per hour)

1.4 2.11

2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.6

1.172.112.12

The conveyor is operating at the proper line speed (no abrupt movement or contact between parts).

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11

2.12

The ground is checked using a 500 volt megohm meter (less than 1megohm resistance).

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/day minimum)

1.41.172.112.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

The venturis in the feed pumps and the pick up tubes in the hopper are checked.

1.4 2.11 2.12

The feed hoses are checked to ensure that they have no excessive bends and kinks.

Per Control Plan/Log Sheet (1/day minimum)

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Page 109: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE D - Powder

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

D2.15 The virgin/reclaim ratio is checked. (feed pressure) Manual

D2.16 Manual

D2.17 Appearance of parts exiting booth is checked. Manual

D2.18 The powder supply and atomizing air pressure are checked. Manual

3.0 Cure (See Convective Cure Process Table I)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

The static pressure gauges on primary and final filters are checked.

Per Control Plan/Log Sheet (1/shift minimum)

1.41.112.122.13

Per Control Plan/Log Sheet (1 per hour)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

Page 110: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

1.0 Pre-Electrocoat Paint Application Part Appearance

E1.1 Manual

2.0 Electrocoat Laboratory

E2.1 2.14 N/A

E2.2 2.14 N/A

E2.3 2.14 N/A

3.0 Electrocoat Tank

E3.1 Automatic/Manual

E3.2 Line speed setup is checked. Automatic/Manual

E3.3 Line speed is verified. Manual Once/week minimum

E3.4 Automatic/Manual

E3.5 Automatic/Manual

E3.6 Flow direction is checked (for monorail system). Manual

E3.7 Flow over the weir is checked. Manual

E3.8 Bath is checked for microbial contamination. Manual

E3.9 Incoming DI / RO water is checked for cleanliness. (conductivity) Automatic/Manual

E3.10 Paint racks are being maintained. Automatic/Manual As needed

E3.11 There is a paint rack maintenance schedule. Manual Required

E3.12 There is a tank clean up schedule. Manual

4.0 Anolyte System

PROCESS TABLE E - Electrocoat

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

1.4 2.11

Incoming parts are inspected for cleanliness and/or uniform phosphate coating (when phosphate is used).

Per Control Plan/Log Sheet (1 per hour)

Laboratory equipment is calibrated and in good working order.

Laboratory standards and reagents are properly stored, labeled, and not expired.

Laboratory records, internal and external, are filed and accessible for review.

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Bath parameters (pH, conductivity, solid content, temperature, voltage) are checked and adjusted.

Per Control Plan/Log Sheet

1.41.6

2.112.12

Per Control Plan/Log Sheet

1.4 2.11 2.12

1.4 2.11 2.12

There is circulation and it is monitored. (flow meter, pressure gage)

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Bag filter pressures are monitored. Bags changed when psi differential. >5-10 PSI.

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/ per week

minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

1.41.172.112.12

1.41.172.112.12

Required (1/year minimum)

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Page 111: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE E - Electrocoat

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

E4.1 Automatic/Manual

E4.2 Automatic/Manual

E4.3 The pH of the anolyte solution has been checked. Automatic/Manual

E4.4 Anodes have been inspected. Manual

E4.5 The anolyte solution is being circulated to each cell. Automatic/Manual

E4.6 Dump and clean schedule for anolyte being maintained. Manual

E4.7 Amperage draw has been checked on each anode. Automatic/Manual

5.0 Rectifier

E5.1 The proper voltage is being used for the load size. Manual per Equip. Mfg.

E5.2 The ramp up time to full voltage has been verified. Automatic/Manual

E5.3 2.10

E5.4 Automatic/Manual

6.0 Rinse System

E6.1 Automatic/Manual

E6.2 There is sufficient permeate supplied to the rinse. Automatic/Manual

E6.3 The pH and conductivity of the rinse have been recorded. Manual

E6.4 There is microbial testing of rinses. Manual

E6.5 Automatic/Manual

E6.6 Rinses have been cleaned per maintenance schedule. Manual

7.0 Cure (See Convective Cure Process Table I)

1.4 2.11 2.12

The anolyte solution is being controlled within the required conductivity limits.

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

The conductivity reading on the anolyte tank has been confirmed in the laboratory.

Per Control Plan/Log Sheet 1 / week

1.4 2.11 2.12

Per Control Plan/Log Sheet (1 per shift)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1 per six months)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet

1.4 2.11 2.12

Per Control Plan/Log Sheet

1.41.6

2.112.12

1.4 2.11 2.12

Per Control Plan/Log Sheet (1 per shift)

There is a safety beacon to alert personnel when system is energized.

1.41.172.112.12

The ripple of the rectifier has been checked by an approved electrician.

Per Control Plan / material supplier

1.4 2.11 2.12

Immersion rinse tanks are operating at the proper levels and tanks are being agitated correctly.

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan / material supplier

1.4 2.11 2.12

The ultrafilters are operating at proper pressures and bag filters are being used. What size bags?

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

Per Control Plan / material supplier

Page 112: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

1.0 Part Appearance

F1.1 Manual

F1.2 1.14 Inspection criteria are posted.

F1.3 2.10 Adequate lighting is in place.

F1.4

F1.5 Paint racks are maintained. Manual

2.0 Paint Mixing

F2.1 Automatic/Manual

F2.2 Manual

F2.3 Manual

F2.4 Manual

F2.5 Manual

F2.6 Manual

F2.7 Automatic/Manual Per Control Plan/Log Sheet

F2.8 Automatic/Manual Per Control Plan/Log Sheet

3.0

F3.1 Manual

F3.2 Automatic

PROCESS TABLE F - Spray

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

1.4 2.11

Incoming parts are inspected for cleanliness, trapped water or water spots as well as uniform phosphate coating (when phosphate is used).

Per Control Plan/Log Sheet (1 per hour)

1.4 2.9

Mutilation prevention items (i.e. gloves, belt buckle covers, watch covers, etc.) are in place.

1.41.172.112.12

1.4 2.11 2.12

Paint mixing rooms are controlled (mixing tank grounding, closed container, properly enclosed space, temperature, clean environment).

Per Paint Manufacturer Recommendation

1.4 2.11 2.12

FIFO system is being utilized.Per Paint Manufacturer

Recommendation

1.4 1.6 1.17 2.11

2.12

Paint agitation/time and reduction (solvent package) are proper and documented.

Per Paint Manufacturer Recommendation

1.4 1.6 1.17 2.11

2.12

Viscosity and temperature are in operational limits and documented.

Per Control Plan/Log Sheet/Paint Manufacturer

Recommendation

1.4 1.6 1.17 2.11

2.12

The proper filter size and type are in place.Per Control Plan/Log

Sheet/Paint Manufacturer Recommendation

1.4 1.6 1.17 2.11

2.12

Pump pressures are set within operational limits.Per Control Plan/Log

Sheet/Paint Manufacturer Recommendation

1.4 2.11 2.12

Circulation (flow meter, pressure gage) is monitored.

1.4 2.11 2.12

Bag filter pressures are monitored (bags are changed when psi differential >5-10 PSI).

Substrate Conditioning (Flame, Plasma, etc) (If applicable)

1.4 2.11

Incoming parts are inspected to ensure that they are free of dirt and contamination.

1.4 1.17 2.11

2.12

Flame/Plasma is set at operational limits per equipment and material supplier recommendations.

Per control plan and equipment and substrate

suppliers recommendations

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Page 113: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE F - Spray

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

F3.3 Manual Per Control Plan

4.0 Primer/Promoter

F4.1 Manual

F4.2 Destaticizing air is operational. (Plastic parts only) Automatic

F4.3 Manual

F4.4 Automatic/Manual

F4.5 Manual

F4.6 Automatic/Manual

5.0 Basecoat (If applicable)

F5.1 Manual

F5.2 Automatic/Manual

F5.3 Automatic/Manual

F5.4 Automatic/Manual

F5.5 Manual

6.0 Basecoat Heated Flash (Waterborne Materials Only)

F6.1 Manual

F6.2 Manual

1.4 2.11 2.13

Final surface tension is within specifications.

1.4 2.11

Incoming parts are inspected to ensure that they are free of dirt and contamination.

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

Per Control Plan/Log Sheet 1 / week

1.4 2.11 2.12

Booth balance is monitored. Per Control Plan/Log Sheet 1 / week

1.4 1.6 1.17 2.11

2.12

Booth temperature and humidity are monitored (or set within operational limits if controlled).

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Film thickness is per customer requirements.Per control plan and

customer requirements

1.4 1.6 1.17 2.11

2.12

Atomizer parameters (fluid flow, air pressures (atomizing fan, shaping), electrostatics and mixing) are set within operational limits.

Per Control Plan/Log Sheet (1 per month minimum)

1.4 2.11

Incoming parts are inspected to ensure that they are free of dirt and contamination.

Per Control Plan / material supplier (once per shift

minimum)

1.4 1.6

2.11 2.13

Flashtimes between coats are set at suppliers recommended times.

Per Control Plan/material supplier

1.4 1.6 1.17 2.11

2.12

Booth temperature and humidity are monitored or set within operational limits if controlled. (Required for waterborne coatings)

Per Control Plan/Log Sheet (1/shift minimum)

1.4 1.6 1.17 2.11

2.12

Atomizer parameters (fluid flow, air pressures (atomizing fan, shaping), electrostatics and mixing) are set within operational limits.

Per Control Plan/Log Sheet (1 per month minimum)

1.4 2.11 2.13

Film builds are per supplier recommendations.Per Control Plan and

suppliers recommendations

1.4 1.6

2.11 2.13

Set point is at suppliers recommended time, temperature and energy type (convection/IR/UV/etc.).

Per Control Plan / material supplier

1.4 1.6

2.11 2.13

Percent solids after pre-dry is at the suppliers recommended percentage.

Per Control Plan/Log Sheet (1/shift minimum)

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Item # Category/Process Steps Control Monitoring

PROCESS TABLE F - Spray

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

F6.3 Manual

7.0 Clearcoat

F7.1 Manual

F7.2 Automatic/Manual

F7.3 Automatic/Manual

F7.4 Automatic/Manual

8.0 Cure (See Convective Cure Process Table I)

9.0 Final Part Inspection

F9.1 1.14

F9.2 2.10

F9.3

F9.4 Manual Per Control Plan

F9.5 Manual Per Control Plan

F9.6 Manual Per Control Plan

1.41.172.112.12

The pre-dry oven is maintained. Per Control Plan / material

supplier

1.4 2.11

Incoming parts are inspected to ensure that they are free of dirt and contamination.

Per Control Plan / material supplier (once per shift

minimum)

1.4 1.6

2.11 2.13

Flashtimes between coats are set at suppliers recommended times.

Per Control Plan/material supplier

1.4 1.6 1.17 2.11

2.12

Booth temperature and humidity are monitored or set within operational limits if controlled. (Required for waterborne coatings)

Per Control Plan/Log Sheet (1/shift minimum)

1.4 1.6 1.17 2.11

2.12

Atomizer parameters (fluid flow, air pressures (atomizing fan, shaping), electrostatics and mixing) are set within operational limits.

Per Control Plan/Log Sheet (1 per month minimum)

Inspection criteria are posted.

There is adequate lighting in inspection area.

1.4 2.9

Mutilation prevention items are in place.

1.4 1.8 1.12

2.13

Defects are being tracked.

1.4 2.13

FTT is being monitored.

1.10 1.11

1.12Scrap and repaints are being tracked.

Page 115: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

1.0 Coating Material Application

G1.1 Manual

G1.2 Automatic/Manual

G1.3 Manual

2.0 Coating Bath

G2.1 Incoming paint viscosity is checked. Manual Each New Lot of Paint

G2.2 Incoming solids checks are performed. Manual Each New Lot of Paint

G2.3 Manual Ongoing

G2.4 Manual Ongoing

G2.5 Paint is kept covered and/or sealed when not in use. Manual Ongoing

G2.6 Manual Ongoing

G2.7 Paint storage room is kept clean. Manual Ongoing

G2.8

G2.9 Paint Temperature. Manual

G2.10 Viscosity. Manual

G2.11 % Solids (by weight). Manual

G2.12 Volume (paint depth in coating vat). Automatic/Manual

G2.13 Vibratory feed tables are cleaned (if used). Manual

PROCESS TABLE G - Dip/Spin

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

1.4 2.11

After pretreatment, parts are inspected for flash rust, wetness, oil or other defects.

Per Control Plan/Log Sheet (each lot)

1.4 2.11

If phosphated, parts are checked for uniformity of phosphate coating.

Per Control Plan/Log Sheet (1/shift minimum)

2.6 1.17

Skids/bins used to hold parts between coating operations are free of oil, grease or other contaminants.

Per Control Plan/Log Sheet (each lot)

1.4 2.11 2.12

1.4 2.11 2.12

1.41.172.112.12

Appropriate mixing equipment is used, capable of dispersing settled solids.

2.9 2.10

Paint is stored properly, away from high humidity and temperature extremes.

2.9 2.10

2.9 2.10

Paint storage room is organized so each paint is easily found to prevent contamination.

2.9 2.10

The following checks shall be performed during production:

1.4 2.11 2.12

Per Control Plan/Log Sheet (3/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (3/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/Day minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (3/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (as needed)

Index PageIndex PageCover PageCover Page

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Item # Category/Process Steps Control Monitoring

PROCESS TABLE G - Dip/Spin

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

G2.14 Manual

G2.15 Paint and/or solvent additions are documented. Manual

G2.16 2.10 Viscosity cups are cleaned after each use. Manual

G2.17 Viscosity cups are verified. Manual 2/Month minimum

G2.18 Thermometers are calibrated/verified. Manual Once/Month minimum

3.0 Application Parameters

G3.1 Automatic/Manual

G3.2 Baskets are kept less than 2/3 full. Automatic/Manual

G3.3 Dip time is controlled. Automatic/Manual

G3.4 Spin speed (RPM) is controlled. Automatic/Manual

G3.5 The coating unit has an attached RPM indicator.

G3.6 RPM's can be adjusted easily.

G3.7 Spin time is controlled. Automatic/Manual

G3.8 Automatic/Manual

G3.9 Automatic/Manual

G3.10 Automatic/Manual

1.4 1.17

2.11 2.12

Basket condition (basket mesh clean and undamaged).

Per Control Plan/Log Sheet (as needed)

1.4 2.11 2.12

Per Control Plan/Log Sheet (each addition)

Per Control Plan/Log Sheet (each check)

2.14 1.17

2.14 1.17

1.4 1.6

A system is in place to ensure proper basket weights for specific parts, such as processing manual, traveller, or process recipe.

Per Control Plan/Log Sheet (each lot)

1.4 1.6

Per Control Plan/Log Sheet (each lot)

1.4 1.6

Per Control Plan/Log Sheet (each lot)

1.4 1.6

Per Control Plan/Log Sheet (each lot)

1.4 1.6 1.17

1.4 1.6 1.17

1.4 1.6

Per Control Plan/Log Sheet (each lot)

1.4 1.6

The number of spins is adjustable (single, double, triple).

1.4 1.6

Tumble time is in/out of coating controlled (if applicable).

Per Control Plan/Log Sheet (each lot)

1.4 1.6 1.17

There is an adequate system to keep parts level going into the oven (raking, vibe table, etc.).

Per Control Plan/Log Sheet (each lot)

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Item # Category/Process Steps Control Monitoring

PROCESS TABLE G - Dip/Spin

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

G3.11 2.10 Vibratory feed tables are cleaned (if used). Manual

G3.12 2.9 Automatic/Manual

G3.13 Parts are cool to to touch before each coating step. Manual Per Control Plan (each lot)

4.0 Cure (See Convective Cure Process Table I)

Per Control Plan/Log Sheet (as needed)

There is evidence of steps taken to assist in soft handling of parts (shallow drops, lined chutes and hoppers, bumper boards, etc.).

Per Control Plan/Log Sheet (each lot)

1.4 2.9 2.11

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Item # Category/Process Steps Control Monitoring

1.0 3.1 Coating Bath

H1.1 Automatic/Manual

H1.2 Time (hoist program) is verified. Automatic/Manual

H1.3 Conveyor speed is verified (if applicable). Manual

H1.4 Temperature is monitored and controlled. Automatic

H1.5 Humidity level is monitored. Automatic/Manual

H1.6 101 (fluoride) and ORP levels are checked. Automatic/Manual

H1.7 Automatic/Manual

H1.8 Bath transfer is maintained. Manual

2.0 1.18 Tap Rinse After Coating

H2.1 Pump pressure or agitator speed is monitored. Automatic/Manual

H2.2 Impurity concentration (conductivity) is checked. Automatic/Manual

3.0 3.2 Reaction Rinse

H3.1 Automatic/Manual

H3.2 Pump pressure or agitator speed is monitored. Automatic/Manual

H3.3 Automatic/Manual

H3.4 There is a dump schedule. Manual

PROCESS TABLE H - Autophoretic

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

1.4 2.11 2.12

Mixer speed and direction are monitored and adjusted.

Per Control Plan/Log Sheet (1/shift minimum)

1.41.6

2.112.12

Per Control Plan/Log Sheet (1/day minimum)

1.41.172.112.12

Annually or after repair

1.41.6

2.112.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (every 2 hours minimum)

1.4 2.11 2.12

Chemical concentration (% solids, starter/iron titration, conductivity) is checked and maintained.

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

Per PM schedule (1/year

minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Chemical concentration (titration, conductivity, pH, Hach Meter Test) is checked and maintained.

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Per Control Plan/Log Sheet (1/shift minimum)

1.4 2.11 2.12

Temperature is monitored and controlled (if applicable).

Per Control Plan/Log Sheet (1/shift minimum)

1.41.172.112.12

Per Chemical Manufacturer's Guideline (minimum 3 times per year)

Index PageIndex PageCover PageCover Page

Page 119: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps Control Monitoring

PROCESS TABLE H - Autophoretic

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Index PageIndex PageCover PageCover Page

4.0 Cure (See Convective Cure Process Table I)

Page 120: Supplier Evaluation (QVR)Rev6 0112

PROCESS TABLE I - Convective Cure

Item #Category/Process Steps Control Monitoring

1.0

I1.1 Automatic

I1.2 1.17 Part temperature profile is monitored. Manual 1/month minimum

I1.3 Proper cure time is maintained (if applicable). Automatic/Manual Per coating supplier recommendation

I1.4 Conveyor speed is maintained (if applicable). Automatic 1/month minimum (after PM)

I1.5 Airflow is measured (if required by coating supplier). Automatic/Manual Per coating supplier recommendation

I1.6 1.17 Air filter change is scheduled. Manual

I1.7 1.17 Thermocouple for oven control is calibrated.

I1.8 2.13 Cure testing is conducted by laboratory. Manual Per coating supplier recommendation

I1.9 2.13 Final color is monitored. Manual

I1.10 2.13 Film thickness/coating weight is monitored. Manual

I1.11 2.13 Gaugeability is checked (if applicable). Manual Per customer requirements

I1.12 2.13 Paint adhesion is monitored. Manual

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

1.41.6

2.112.12

Oven temperature set point and limits are checked and documented.

1/shift minimum or at every material change. Per coating supplier

recommendation

1.41.6

2.112.12

1.41.6

1.172.112.12

1.4 2.11 2.12

Per oven manufacturer, filter supplier recommendation

Per Control Plan/Log Sheet (1/shift or color change minimum)

Per Control Plan/Log Sheet (1/shift or color change minimum)

Per Control Plan/Log Sheet (1/shift or color change minimum)

Index PageIndex PageCover PageCover Page

Page 121: Supplier Evaluation (QVR)Rev6 0112

PROCESS EQUIPMENT

Item # Pretreatment E-Coat Spray Dip/Spin A-Coat Cure Verification Frequency Comment

1.1 2.14 X X X X X pH Meter/Probe Daily Yearly1.2 2.14 X X X X X X X Temperature Controller At Start-up 2x/Year1.3 2.14 X X Rectifier At Start-up N/A

1.4 2.14 X X X X X Wet Analysis N/A

1.5 2.14 X Atomic Absorption (Optional)1.6 2.14 X X X X X X X Filters * N/A * As needed based on pressure.1.7 2.14 X X X Balance 1x/Week Yearly1.8 2.14 X X Coductivity Meter Before Use Yearly1.9 2.14 X X Viscosity Measurement Hourly Monthly1.10 2.14 X Thermocouple N/A 2x/Year

MINIMUM REQUIRED TESTING CAPABILITY2.1 2.14 X X X X X X Salt Spray Cabinet2.2 2.14 X X X X X Water Immersion Tank2.3 2.14 X Environmental Chamber2.4 2.14 X Cure Testing (chemical rubbing)2.5 2.14 X X X X X X Adhesion Testing 2.6 2.14 X X X X X X Thickness Testing2.7 2.14 X X X X X X Microscope (when applicable)2.8 2.14 X Freezer (plastic substrate)2.9 2.14 X Lab Oven

PROCESS TABLE J - EQUIPMENT

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related CSA Question #

Powder Coat

Calibration Frequency

Phosphate - 3hr min. Paint Lines - Before Run

E-Coat - 1x/Shift min.

Cover PageCover Page Index PageIndex Page

Page 122: Supplier Evaluation (QVR)Rev6 0112

CQI-15 WELDING SYSTEM ASSESSMENTInstructions for completing the Cover Sheet

1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and WeldingSpecialist) or different management system, then these locations shall be considered as separate facilities.

2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.

3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.

4 Fax number: The fax number of the facility.

5 Number of Welding Employees at this Facility: The number of employees, salaried and hourly, associated with the welding operation at this facility.

6 Captive Welder (Y/N): Enter "Y" if this facility welds components for their own company. Enter"N" if the company does not weld any components for their own company.

7 Commercial Welder (Y/N): Enter "Y" if this facility welds components for companies other thantheir own company. Enter "N" if this facility does not weld any components for other companies.

8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.

9 Date of Previous Assessment: List the date of the previous CQI-15 Special Process: WeldingSystem Assessment of this facility.

10 Type(s) of Welding at this Facility: Place a checkmark to designate the welding process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the WeldingSystem Assessment.

11 Current Quality Certification(s): the welder shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.

12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the wleder shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.

13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the welder's organization.

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14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).

15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.

16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.

17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.

Page 124: Supplier Evaluation (QVR)Rev6 0112

CQI-15 WELDING SYSTEM ASSESSMENT

Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and WeldingSpecialist) or different management system, then these locations shall be considered as separate facilities.

Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.

Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.

Fax number: The fax number of the facility.

Number of Welding Employees at this Facility: The number of employees, salaried and hourly, associated with the welding operation at this facility.

Captive Welder (Y/N): Enter "Y" if this facility welds components for their own company. Enter"N" if the company does not weld any components for their own company.

Commercial Welder (Y/N): Enter "Y" if this facility welds components for companies other thantheir own company. Enter "N" if this facility does not weld any components for other companies.Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.

Date of Previous Assessment: List the date of the previous CQI-15 Special Process: WeldingSystem Assessment of this facility.

Type(s) of Welding at this Facility: Place a checkmark to designate the welding process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the WeldingSystem Assessment.

Current Quality Certification(s): the welder shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.

Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the wleder shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.

Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the welder's organization.

Cover PageCover Page Index PageIndex Page

Page 125: Supplier Evaluation (QVR)Rev6 0112

Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).

Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.

Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.

Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.

Page 126: Supplier Evaluation (QVR)Rev6 0112

Special Process: Welding System Assessment

Facility Name:Address:

Phone Number:

Fax Number:

Number of Welding Employees at this Facility:

Captive Weld Organization (Y/N)

Date of Assessment:

Date of Previous Assessment:

Current Quality Certification(s)

Date of Re-assessment (if necessary):Personnel Contacted:Name Title

0 00 00 00 0

Commercial Weld Organization (Y/N)

Page 127: Supplier Evaluation (QVR)Rev6 0112

Auditors/AssessorsName Company

0000

Number of "Not Satisfactory" Findings

Number of "Needs Immediate Action" Findings

Number of "Fail" Findings in the Job Audit(s)

© 2010 Automotive Industry Action Group (AIAG)

Page 128: Supplier Evaluation (QVR)Rev6 0112

Special Process: Welding System Assessment

Facility Name:Address:

Type(s) of Weld Processing at this Facility:

Process Table A - Arc WeldingArc Stud/Fastener WeldingFlux Cored Arc WeldingGas Metal Arc WeldingSubmerged Arc WeldingShielded Metal Arc Welding

Plasma Arc Welding

Gas Tungsten Arc Welding

Gas Metal Arc Braze Welding

Process Table B - Resistance Welding

Resistance Spot WeldingProjection WeldingResistance Seam Welding

High-frequency Seam WeldingInduction Seam WeldingMash Seam WeldingFlash WeldingProcess Table C - Laser WeldingNd YAG WeldingCO2 WeldingDiode WeldingWire FedProcess Table D - Solid State WeldingInertia Friction Welding

Direct Drive Friction WeldingFriction Stir WeldingFlash Butt WeldingResistance Butt WeldingUltrasonic Welding

Date of Re-assessment (if necessary):

Phone Email

Cover PageCover Page Index PageIndex Page

Page 129: Supplier Evaluation (QVR)Rev6 0112

Phone Email

Page 130: Supplier Evaluation (QVR)Rev6 0112

Special Process: Welding System Assessment

Question Requirements and Guidance

Section 1 - Management Responsibility & Quality Planning

1.1

1.2

1.3

1.4

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a

violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group

Question Number

Is there a dedicated and qualified technical welding

person on-site?

To ensure readily available expertise, there shall be a dedicated and qualified welding person on site. This individual shall be one of the following: Degreed Welding Engineer, or equivalent science degree, Certified Welding Inspector from approved internationally recognized body, or person agreed upon between customer and supplier. This person shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including metallurgical and welding knowledge. The qualifications shall include a minimum of 5 years experience in welding operations or a combination of a minimum of 5 years of formal metallurgical education and welding experience.

Is there a responsibility matrix to ensure that all key

management and supervisory functions are performed by

qualified personnel?

The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management and customer at all times.

Do you use only qualified welders (personnel)?

The organization shall provide employee training for all welding operations specific to their job function. All welding employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees were trained; the evidence shall include an assessment of the effectiveness of the training, must prove knowledge of the customer's specific requirements and internal standards, and where appropriate, employee certification, such as for a manual welder. Management and customer shall define the qualification requirements for each function and ongoing or follow-up training shall also be addressed.

How do you maintain welder certification?

Required qualification maintenance. If the welder has not welded in the specific operation in a 6 month time frame, the welder must be requalified to that operation. Based on the welder's quality performance, it must be established when retraining and requalification of the individual must be performed.

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1.5

1.6

1.7

1.8

Is set-up practice in compliance with documented

work instructions?

Set-up verification to the procedures (as example: equipment settings, clamping sequence, weld sequence, direction of travel and other process controls) in compliance to documented work instructions.

Does the welding organization perform advanced quality

planning?

The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The welding organization shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.

Are welding FMEA's up to date and reflecting current

processing?

The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEA's are updated to reflect current part quality status.The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key welding process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.

Are welding process control plans up to date and reflecting

current processing?

The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls. The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. They shall address all process steps from part receipt to part shipment and identify all equipment used and all essential welding process parameters as defined by the relevant individual process tables or non-essential as agreed upon between supplier and customer. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEA's. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables.

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1.9

1.10

1.11

Are all welding related and referenced specifications

current and available? For example: SAE, AIAG, ASTM, ASME, AWS, ISO, General

Motors, Honda, Ford, Toyota and Chrysler.

To ensure all customer requirements are both understood and satisfied, the organization shall have all specifically related welding and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications may include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, ASME, AWS, ISO, General Motors, Honda, Ford, Toyota, and Chrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards/specifications and changes based on customer-required schedule. Timely review should be as soon as possible and shall not exceed two working weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify whois responsible for performing these tasks.

Is there a written process specification for all active

processes?

The welding organization shall have written process specifications for all active processes and repair processes which identify all steps of the process including relevant operating parameters. Examples of operating parameters as defined by the relevant process tables. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control.

These process specifications may take the form of work instructions, job card, set-up sheets, or other similar documents.

Has a valid product capability study been performed initially and after process changes?

The organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, and after a major process change of any equipment or parameter. The organization and customer shall define what constitutes a major process change. Initial product capability studies shall be conducted for all welding processes per each process path defined in scope of work and in accordance with customer requirements. In the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to be followed in case capability indices fall outside customer requirements or established ranges.

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1.11

1.12

1.13

1.14

1.15

1.16

1.17

Has a valid product capability study been performed initially and after process changes?

Each process path includes all combinations of equipment that are integrated in the performance of a welding process, e.g., weld cell with A and B side fixture feeding another weld cell with A and B side fixture or multiple machines. Capability study techniques shall include boundary sample conditions as defined by the control plan that are robust and meet all customer requirements. Example, any combination of tolerances as defined by Process Tables.

Does the welding organization monitor and analyze data over time, and react to this data?

The analysis of products or processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or essential process data over time.Methods of analysis shall include ongoing trend or historical data analysis of product or process parameters. The organization shall determine which parameters to include in such analysis.

Is management reviewing the weld control system at a

frequency determined by the control plan?

Management shall review the weld process control systems. The management review shall include efforts to detect out-of-control conditions or alarm conditions. The process of reviewing the control system shall be documented and recorded in the control plan.

Are internal assessments being completed on an annual

basis, at a minimum, using AIAG WSA?

The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG WSA. Concerns shall be addressed in a timely manner.

Does the Quality Department review, address, and

document customer and internal concerns?

The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.

Is there a continual improvement plan applicable

to each process defined in the scope of the assessment?

The welding organization shall define a process for continual improvement for their welding processes identified in the scope of the WSA. The continual improvement process shall be designed to bring about improvements in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.

Does the Quality Manager or designee authorize the

disposition of material from quarantine status?

The Quality Manager or designee is responsible for authorizing and documenting the disposition of quarantined material.

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1.18

1.19

1.20

1.21

1.22

1.23

Are there procedures or work instructions available to the

welding personnel that define the welding process?

There shall be procedures or work instructions available to welding personnel covering the welding process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, safety, house-keeping, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.

Is there a preventive maintenance program? Is maintenance data being

utilized to form a predictive maintenance program?

The organization shall have a documented preventive maintenance program for process equipment (as identified by the Process Tables). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner.Company data, e.g., downtime, quality rejects, first-time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Maintenance data shall be collected and analyzed as part of a predictive maintenance program.

Has the welding organization developed a critical spare part list and are the parts available

to minimize production disruptions?

The welding organization shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.

How does the organization document and respond to

quality spills, nonconformance, customer

concerns?

Reaction plans are to be followed per the control plan and PFMEA or, in the case of newly indentified issues PFMEA and control plan must be updated to reflect the new failure mode and reaction steps taken.

What is the process deviation requirements of your

customer?

If there are to be changes in process outside of the current control plan and last agreed upon process and parts sign off, do you know what your customer requirements are, have you notified your customer, and do you have customer approval prior to making the change?

Is there a system in place to authorize reprocessing and repair? Is it documented?

The quality management system shall include a documented process for reprocessing and repair that shall include authorization from a customer designated individual. The process shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible. Any reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary welding modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.

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Section 2 - Floor and Material Handling Responsibility

2.1

2.2

2.3

2.4

2.5

2.6

Does the facility ensure that the data entered in the

receiving system matches the information on the customer's

shipping documents?

It is critical that all customer requirements and lot identification be adequately transferred to internal welding documents. The facility shall ensure that the data entered in the receiving system match the information on the customer's shipping documents. Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. Sometimes the material received does not precisely correspond to customer shipping documents. The facility shall have a detailed process in place to resolve receiving discrepancies.The requirements stated above also apply to captive welding departments. This process refers to receiving and shipping the parts in and out of the welding department.

Is product clearly identified and staged throughout the

welding process?

Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the welding process. Non-welded, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.

Is lot traceability and integrity maintained throughout all

processes?

Out-going lot(s) shall be traceable to the incoming lot(s).The discipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.

Are procedures adequate to prevent movement of non-conforming product into the production system?

The control of suspect or non-conforming product is required to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification, and tracking of material flow in and out of the hold area. A non-conforming hold area shall be clearly designated to maintain segregation of such material.

Are containers free of inappropriate material and

contaminants?

Containers handling customer product shall be free of inappropriate material and contaminants. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming welded parts or inappropriate material contaminate the finished lot.

Is part loading specified, documented and controlled?

Loading parameters shall be specified, documented, and controlled. Examples include part load sequence and clamp sequence.

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2.7

2.8

2.9

2.10

Section 3 - Equipment / Facilities/Controls

3.1

3.2

3.3

Is there a containment reaction plan and are

operators trained in the process?

Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment/reaction plans related to all elements of the welding process. Evidence shall exist showing disposition and traceability of affected product. Unplanned or emergency downtime greatly raises the risk of improper processing.

Is the handling, storage and packaging adequate to

preserve product quality?

The welder’s loading system, in-process handling, and shipping process shall be assessed for risk of part damage or other quality concerns.Other practices such as stacking of overloaded containers can also increase the risk of part damage.

Are plant cleanliness, housekeeping, environmental

and working conditions conducive to control and

improved quality?

Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality. The welding organization shall evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for conditions that are detrimental to quality processing such as loose parts on floor, contaminants, oil, inadequate plant lighting, fumes, etc.

Are parts free from contaminants that would be detrimental to the quality of

the welding processes, subsequent processes, or the

product?

Parts shall be free from contaminants that are detrimental to the quality of the welding processes, subsequent processes, or the product. If applicable, pre-wash and post-wash parameters shall be monitored and documented.

Are the facilities sufficient for the welding operation?

This could include but is not limited to, facilities capabilities such as safely, environmental regulations/practice, sufficient incoming power (balance and loading), air (sizing, filtering and cleanliness), water, power supply grounding per OEM and regulatory specifications, gas mixing system (equipment and sizing), ventilation, and adequate lighting.

Are the power supplies sufficiently sized?

The power supply should be adequate for the manufacturing process with consideration not limited to output energy, duty cycle, cooling, flow rates and grounding.

Are process equipment calibrations and/or verification

certified, documented, available, and current?

The calibration and certification of the process equipment shall be checked at regular specified intervals. Refer to the applicable Process Tables.

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3.4

3.5

3.6

Section 4 - TOOLING/FIXTURING

4.1

4.2

4.3

4.4

4.5

Section 5 - PROCESS CONTROLS AND CONFIRMATION

5.1

5.1.1

5.1.2 With over rides or resets, logs must be maintained.

5.1.3 Weld faults audible, visible and line shut down.

Has a preventative maintenance program been

established and documented?

Supplier shall have a preventative maintenance program that is documented and implemented. Refer to Section 1.19 and the applicable Process Tables.

Have the necessary replacement parts and

process consumables been identified and made readily

available?

The replacement parts and process consumables shall be identified, maintained in the appropriate volumes and proper storage. Consumables must be on the customer's approved source list (if applicable). Refer to the applicable Process Tables, Section 2.0 and Section 1.19. This shall be captured in tools such as the set up procedure, PFMEA and Control Plans. It should be included in the layered process audit or other similar type quality review process.

Are the process, equipment, and safety alarm checks

being tested at the required frequency or after any repair

or rebuild?

The welding operation shall have a list of welding process, equipment, and safety alarms. These alarms shall be individually tested at the required frequency as listed in the control plan, and after any repair, process change or rebuild. These checks shall be documented.

Is there a record of the design and set-up of the fixture?

Supplier shall have documentation of the fixture design, that are stored properly and accessible. Proper identification and revision level on the fixture or related to the fixture. Documented fixture set-up (i.e., clamps, pins, locating devices)

Is the positioning of each part being controlled?

A method to detect proper fixture and part position is required for each part, such as the use of proximity switches, optical sensors, mechanical probes, part presence or poke yokes., etc.

Has fixturing/tooling preventative maintenance

program been established?

Supplier shall have a preventative maintenance program that is documented and implemented. Refer to Section 1.18 and the applicable Process Tables. Examples: cleaning, degreasing, and fixturing integrity.

Are the fixture components robust?

Gas, air, sensors, control cables, etc. are adequately protected for the process environment.

Are the tooling components designed for the welding

process?

Fixturing/tooling was developed considering movement, reach, accessibility, tool center point, maintenance, and ergonomics (manual, automatic, and robotics)

Does welding operation include the following?

Identify the process control equipment necessary to monitor, control and provide feedback on all essential process variables as listed below and in the applicable Process Tables.

Logic has been established to effectively identify and address process or equipment faults.

Page 138: Supplier Evaluation (QVR)Rev6 0112

5.1.4

5.1.5 Calibration of meters and system controls.

5.1.6

5.1.7

5.1.8 High/Low limit alarms established by actual data.

5.1.9

5.1.10 Acceptable traceability (sequence/date coding)

5.1.11 All tooling and process changes are documented.

5.1.12

5.1.13 Change over procedure (filler material, fixtures)

5.1.14

5.2

5.3

5.4

5.5

5.6

5.6.1 Cut and etch

5.6.2

5.6.3 Correct number of welds

5.6.4 Weld length/size

5.6.5 Weld location

5.6.6 Non Destructive Testing (NDT)

At weld cycle interrupt, part must not be removed or passed until dispositioned by appropriate personnel.

Inter-locking of previous operations have occurred and quality of parts has been verified before the next operation begins.

Secure backups of all programs and procedures (electronic preferred).

Process variables have been defined and developed by data and shown to be statistically capable.

Documented welding procedures for each weld location and each process variable.

Must have documented start-up and shut-down procedure.

Are process control parameters monitored at established frequencies?

Process control parameters shall be monitored per frequencies established in the control plan. An appropriate person shall verify the process control parameters. Management review is required per Question 1.13.

How does the organization review and react to out of

control/specification parameters?

Are there documented reaction plans with appropriate levels of containment for both out of control and out of tolerance process parameters? Is there documented evidence that reaction plans are followed?

How does the organization handle changes to process

control parameters after initial customer approval?

There shall be a hierarchy established for making and approving process changes. Each process should be acted on according to the level of change. Review process changes with your customer.

Are In-Process and Final Tests performed at

established frequencies?

In-Process and Final Tests shall be performed per frequencies in the control plan as agreed upon between the supplier and the customer.

Are weld quality requirements clearly defined per customer

specifications?

Weld quality requirements per internal and customer specifications, such as but not limited to the following testing methodology:

Part location, warping, gap, and dimensional requirements

Page 139: Supplier Evaluation (QVR)Rev6 0112

5.6.7 Spatter, undercut, porosity, discontinuities,…

5.6.8 Weld direction confirmation

5.6.9 Destructive testing

5.6.10 Additional testing

© 2010 Automotive Industry Action Group (AIAG)

Page 140: Supplier Evaluation (QVR)Rev6 0112

Special Process: Welding System Assessment

Assessment

Objective Evidence N/A Satisfactory Not Satisfactory

Section 1 - Management Responsibility & Quality Planning

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a

violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group

Needs Immediate Action

Cover PageCover Page Index PageIndex Page

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Section 2 - Floor and Material Handling Responsibility

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Section 3 - Equipment / Facilities/Controls

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Section 4 - TOOLING/FIXTURING

Section 5 - PROCESS CONTROLS AND CONFIRMATION

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Section 6 - Job Audit

Job Identity:Customer:Shop Order Number:Part Number:Part Description:Base Metal Specifications:Filler Metal Specification (if required):Welding Process(es):

Question # Job Audit Question

6.1

6.25.1

6.3Are over rides or resets logs maintained? 5.1.2

6.45.1.3

6.5

6.6

6.7

6.8

6.9

6.105.1.9

6.11

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group

RelatedWSA Question #

Has the welding operation identified the process control equipment necessary to monitor, control and provide feedback on all essential process variables as listed in the applicable Process Tables?

1.85.15.2

Has the logic been established to effectively identify and address process or equipment faults?

Are weld faults audible, visible and does the line shut down?

If the weld cycle is interrupted, is the part controlled or contained until dispositioned by appropriate personnel?

2.75.1.4

Are the meters and feed back controls calibrated per established frequencies?

5.1.53.3

If applicable, is there an inter-locking of the previous operation and has the quality of parts been verified?

5.1.6

Are there secure backups of all programs and procedures (electronic preferred)?

5.1.7

Are high/low limit alarms established by actual data.

5.1.85.1.1

Have process variables been defined and developed by data and shown to be statistically capable?

Is there acceptable traceability (sequence/date coding)?

5.1.105.1.11

2.32.7

Page 151: Supplier Evaluation (QVR)Rev6 0112

6.12

6.13

6.14

6.15

6.165.2

6.17

6.18

6.19

6.20

6.20.1 Test Type:

Test Method:

Test Frequency and Quantity:

Specification:

6.20.2 Test Type:

Test Method:

Test Frequency and Quantity:

Specification:

6.20.3 Test Type:

Test Method:

Test Frequency and Quantity:

Specification:

6.20.4 Test Type:

Is there traceability of all process and tooling changes?

4.15.1.11

5.4

Are there documented welding procedures for each weld location and each process variable?

5.1.121.5

1.10

Is there a documented change over procedure (filler material, fixtures)?

1.55.1.13

3.6

Is there a documented start-up and shut-down procedure?

1.51.10

5.1.14

Are process control parameters monitored at established frequencies?

Are there documented reaction plans with appropriate levels of containment to both out of control and out of tolerance process parameters and provide documented evidence that reaction plans are followed?

5.31.215.61.82.7

How does the organization handle changes to process control parameters after initial customer approval and how do you notify your customer?

1.65.4

1.221.16

Are In-Process and Final Tests performed at established frequencies?

1.85.5

Are weld quality requirements clearly defined per customer specifications?

1.95.6

Page 152: Supplier Evaluation (QVR)Rev6 0112

Test Method:

Test Frequency and Quantity:

Specification:

© 2010 Automotive Industry Action Group (AIAG)

Page 153: Supplier Evaluation (QVR)Rev6 0112

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group

Customer or Internal Requirement

Job (Shop) Order or Reference Documentation

Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

Cover PageCover Page Index PageIndex Page

Page 154: Supplier Evaluation (QVR)Rev6 0112

Each part may have one or more requirements determined by the welding specification. Parts must meet each requirement. List requirements below and validate.

Page 155: Supplier Evaluation (QVR)Rev6 0112
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Item # Category/Process Steps

1.0 1.7, 1.8

A1.1 Arc voltage

A1.2 Amperage

A1.3 Current type (AC/DCEN/DCEP)

A1.4 Wire feed speed

A1.5

A1.6 Stud gun/torch position work angle, travel angle

A1.7 Contact tip-to-work distance

A1.8 Electrode-to-work distance

A1.9 Lift height of stud

A1.10 Fastener coating (determines current type)

A1.11 Plunge control mode force or position

A1.12 Flux classification and depth

A1.13 Flux removal and reclaimation plan

A1.14 Gas flow pre-flow, post-flow, rate and type(s)

A1.15

A1.16 Travel speed

A1.17 Gas nozzle size and type

A1.18 Arc starting parameters

A1.19 Arc end parameters

PROCESS TABLE A- Arc Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service

marks of the Automotive Industry Action Group

All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable". X indicates an essential variable which shall be documented and controlled.ü indicates that procedure should be reviewed and documented when necessary.

Related WSA Question #

Arc welding specific essential variables which shall be addressed in the FMEA, control plan and welding procedures

Pulse setting variables specific to the OEM of the welding equipment must be documented and controlled.

Electrode and/or filler metal type, diameter, and classicifacation

Page 157: Supplier Evaluation (QVR)Rev6 0112

A1.20 Wire burnback settings

A1.21 Plunge depth

A1.22 Arc time

A1.23 Fastener geometry per material type

A1.24 Nozzle cleaning and cleaners, replacement

A1.25 Tip changes

A1.26 Wire liners/conduits cleaning and replacing

A1.27 Drive roll changes

A1.28 Wire guide tube change

A1.29 Antispatter Application (spray/dip and equipment)

A1.30 Electrode and stud collet change

A1.31 O rings in gas system maintenance

A1.32 Gas delivery and mixing system

A1.33 Flux delivery systems maintenance

A1.34 Flux removal (screens size and magnetic separators)

A1.35 Electrode sharpening

A1.36 Slag removal

A1.37 Wire dereelers maintenance

A1.38 Wire brake adjustment

A1.39 Integrity of ground system

© 2010 Automotive Industry Action Group (AIAG)

What are your procedures for:

x1: Processes can be used both with and without filler metal.

x2: These welding processes are designated for either gas shielded, self shielded or gasless.

x3: Arc Spot welding applicactions only.

Page 158: Supplier Evaluation (QVR)Rev6 0112

x x x x x

x x x x x x x

x x x x x x x

x x x

x x x

x x x x x x x

x x xü x x

x

x

x

x

x

x x x

x

x x x x

x x x ü x x

x x x

x x x ü x x

x x x x x

PROCESS TABLE A- Arc Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service

marks of the Automotive Industry Action Group

All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming

X indicates an essential variable which shall be documented and controlled. indicates that procedure should be reviewed and documented when necessary.

Arc Stud/ Fastener Welding (SW)

Flux-Cored Arc Welding (FCAW)

Gas Metal Arc Welding (GMAW)

Submerged Arc Welding (SAW)

Shielded Metal Arc Welding (SMAW)

Plasma Arc Welding (PAW)

Gas Tungsten Arc Welding (GTAW)

x1 x1

x2 x2

x1 x1

x2 x2

Cover PageCover Page Index PageIndex Page

Page 159: Supplier Evaluation (QVR)Rev6 0112

x x x

x

x

xü ü ü ü ü

ü ü ü ü

ü ü üü ü ü

ü ü ü

ü ü

ü ü

ü ü ü ü ü

x x xü

ü

ü ü

x x xü ü ü

ü ü ü

ü ü ü ü ü ü ü

x3 x3 x3 x3

x2 x2

: These welding processes are designated for either gas shielded, self shielded or gasless.

Page 160: Supplier Evaluation (QVR)Rev6 0112

x

x

x

x

x

x

x

x

x

x

x

x

x

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming

Gas Metal Arc Braze Welding

Index PageIndex Page

Page 161: Supplier Evaluation (QVR)Rev6 0112

x

ü

ü

üü

ü

ü

ü

x

ü

ü

ü

Page 162: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps

2.0 1.7, 1.8

B2.1 Weld force

B2.2 Clamp force

B2.3 Forge force

B2.4 Forge delay

B2.5 Amperage

B2.6 Voltage

B2.7 Power

B2.8 Frequency

B2.9 Pulsation

B2.10 Squeeze time/cycles

B2.11 Weld time/cycles

B2.12 Hold time/cycles

B2.13 Quench time/cycles

B2.14 Temper time

B2.15 Cool time/cycles

B2.16 Upslope time/cycles

B2.17 Stepper programs

B2.18 Tip/electrode/wheel dressing

B2.19 Weld travel speed

B2.20 Adequate electrode follow up in weld force / distance

B2.21 System cooling-transformers, electrodes, etc.

PROCESS TABLE B- Resistance Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action

Group are registered service marks of the Automotive Industry Action Group

All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable". X indicates an essential variable which shall be documented and controlled.ü indicates that procedure should be reviewed and documented when necessary.

Related WSA Question #

Resistance welding specific essential variables which shall be addressed in the FMEA, control plan and welding procedures

Page 163: Supplier Evaluation (QVR)Rev6 0112

B2.22 Tip/electrode/wheel/coil change frequency

B2.23 Tip/electrode/wheel/coil alignment

B2.24 Electrode selection/type (material type etc.)

B2.25 Electrode geometry

B2.26 Induction coil geometry

B2.27

B2.28 Projection weld geometry and size

*Flash Welding is a Solid State process, however, the process controls most resemble a resistance weld process.Refer to Table D for other requirements on Flash Welding

© 2010 Automotive Industry Action Group (AIAG)

What are your procedures for:

Secondary loop electrical conductors (cables, leaf shunts, etc.) and mechanical joints maintenance

Page 164: Supplier Evaluation (QVR)Rev6 0112

X X X X Xü ü ü

ü ü ü

ü ü

X X X X

X X X X ü

ü ü

X X X X X X X

X X X X

X X X X

X X X X X

X X X X Xü ü ü ü ü ü ü

ü ü ü ü ü ü ü

X X X X

X X X X X X X

X

X X X X X X

X X X X

X X X

X X X X X X X

PROCESS TABLE B- Resistance Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action

Group are registered service marks of the Automotive Industry Action Group

All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is

X indicates an essential variable which shall be documented and controlled. indicates that procedure should be reviewed and documented when necessary.

Resistance Spot Welding (RSW)

Projection Welding (PW)

Resistance Seam Welding (RSEW)

High-Frequency Seam Welding (RSEW-HF)

Induction Seam Welding (RSEW-I)

Mash Seam Welding (RSEW-MS)

Flash Welding* (FW)

Cover PageCover Page Index PageIndex Page

Page 165: Supplier Evaluation (QVR)Rev6 0112

X X X X X X X

X X X X X X Xü ü ü ü ü ü

ü ü ü ü ü ü

ü

ü ü ü ü ü ü ü

ü

*Flash Welding is a Solid State process, however, the process controls most resemble a resistance weld process.

Page 166: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps

3.0 1.7, 1.8

Equipment

C3.1 Beam quality

C3.2 Optic cleanliness

C3.3 Cross jet or laser knife

C3.4 Beam configuration (split, single)

C3.5 Focal length

C3.6 Beam spot size

C3.7 Gas tube angle/arrangement

C3.8 Optics purge gas (flow and quality)

C3.9 Mirror cleanliness

C3.10 Mirror degradation

C3.11 Beam sharing

C3.12 Split beam

C3.13 Tip changes

C3.14 O rings in gas system

C3.15 Gas nozzle

C3.16 Torch angles

C3.17 Chillers (internal - external)

C3.18 - Flow rate

C3.19 - Water quality

PROCESS TABLE C- Laser Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable". X indicates an essential variable which shall be documented and controlled.ü indicates that procedure should be reviewed and documented when necessary.

Related WSA Question #

Welding specific essential variables which shall be addressed in the FMEA, control plan and welding procedures

Page 167: Supplier Evaluation (QVR)Rev6 0112

C3.20 - Type of coolant

C3.21 - Additive concentration

C3.22 - Temperature control (rate of change and range)

C3.23 Wire feed system

C3.24 - Wire feed speed

C3.25 - Wire liners/conduits cleaning and replacing

C3.26 - Drive roll changes

C3.27 - Wire guide tube

C3.28 - Wire derealers

C3.29 - Wire brake adjustment

C3.30 - Wire cleaners/wipers

C3.31 - Contact tip to work distance

C3.32 - Wire position to laser focal point

Beam Delivery

C3.33 Direct

C3.34 Fiber

C3.35 - Fiber diameter

C3.36 - Fiber lengths

C3.37 - Bend radius

C3.38 - Condition of fiber

C3.39 - Fiber ends (condition of fiber ends)

C3.40 - Fiber end cooling

C3.41 Mirror

C3.42 - Power loss though the delivery system

C3.43 - Alignment

C3.44 - Cleanliness

C3.45 - Coatings of mirror

C3.46 - Mirror type

C3.47 - Optic and mirror cooling

Process Variables

C3.48 Shielding gas type - flow rate

C3.49

C3.50 Power Output Control

C3.51 Power ramping/program (start, weld, end)

C3.52 Power at the work piece

C3.53 Offset of beam to joint

C3.54 Continuous wave

C3.55 Pulsation

C3.56 Angle of Incidence

C3.57 Focus point

Weld travel speed control (rate of change, and velocity control)

Page 168: Supplier Evaluation (QVR)Rev6 0112

C3.58 Direction of welding (trailing or lead)

C3.59 Beam quality burn-in

C3.60 Power output control calibration

C3.61 Plasma suppression

C3.62 - Monitoring Back scatter for control process

Fixtures/Part

C3.63 - Stability and/or vibration isolation

C3.64 - Articulation system (smoothness of motion and accuracy)

C3.65 Part fit up

C3.66 Seam tracking

C3.67 Edge condition

C3.68 Coatings

© 2010 Automotive Industry Action Group (AIAG)

What are your procedures for controlling:

Page 169: Supplier Evaluation (QVR)Rev6 0112

X X X X

X X X X

X X X X

X X X X

X X X X

X X X X

X X X X

X X

X X X

X X X

X X X X

X X X X

X

X

X

X

X X X X

X X X X

X X X X

- Laser Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action

All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.

X indicates an essential variable which shall be documented and controlled. indicates that procedure should be reviewed and documented when necessary.

Nd YAG (LBW)

CO2 (LBW)

DIODE (LBW)

With Wire Feed

System

Cover PageCover Page Index PageIndex Page

Page 170: Supplier Evaluation (QVR)Rev6 0112

X X X X

X X X X

X X X X

X

X

X

X

X

X

X

X

X

X

X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X

X X

X X

X X

X X

X X

X X

X X X X

X XX X

X X X X

X X X X

X X X X

X X X X

X X X X

X X X X

X X X X

X X X X

Page 171: Supplier Evaluation (QVR)Rev6 0112

X X X X

X X X X

X X X X

X Xü ü ü ü

X X X X

X X X Xü ü ü ü

ü ü ü ü

ü ü ü ü

ü ü ü ü

Page 172: Supplier Evaluation (QVR)Rev6 0112

Item # Category/Process Steps

4.0 1.7, 1.8

D4.1 Tolerances on axial alignment

D4.2 Faying surface area

D4.3 Faying surface cleanliness

D4.4 Initial spindal speed

D4.5 Welding spindal speed

D4.6 Spindal torque - to not damage equipment

D4.7 Flywheels; total moment of inertia

D4.8 Spindle clamp pressure

D4.9 Fixture clamp pressure

D4.10 Part stickout

Preheat (First friction phase) if needed

D4.11 -Projection on faying surface

D4.12 -Preheat force

D4.13 -Preheat time or RPM

D4.14

Weld Heat (Second friction phase)

D4.15 -Friction weld force

D4.16 -Friction speed at which forging begins

Forging Stage

D4.17 -Forging speed

D4.18 -Forge force

PROCESS TABLE D - Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the

Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable". X indicates an essential variable which shall be documented and controlled.ü indicates that procedure should be reviewed and documented when necessary.

Related WSA Question #

Welding specific essential variables which shall be addressed in the FMEA, control plan and welding procedures

Preheat burnoff length-amount of dimension loss during preheat

Page 173: Supplier Evaluation (QVR)Rev6 0112

D4.19 -Forge time

D4.20 -Forge length if limited upset is used

D4.21 -Forge delay

D4.22 -Upset distance

D4.23 -Upset removal / management

D4.24 -Upset hold time

D4.25 -Upset rate

D4.26 -Friction upset distance and time

D4.27 Brake setting or stopping time dimensions and tolerences

D4.28 Brake force

D4.29 Brake delay prior to upset

D4.30 Final position

D4.31 Postweld heat treatment if needed based on materials joined

D4.32 Protective atmosphere if necessary for the base material

D4.33 Total burnoff-amount of dimension loss during total process

FSW

D4.34 Primary control (position or force)

D4.35 Tool to weld joint alignment during length of travel

Tool

D4.36 -Pin to shoulder ratio

D4.37 -Pin length

D4.38 -Included angle for pin

D4.39 -Included angle for shoulder

D4.40 -Thread on pin surface

D4.41 -Pin material

Plunge Practice

D4.42 -Speed of plunge

D4.43 -Spindal speed during plunge

D4.44 -Preheat dwell time after plunge

D4.45 -Plunge force

Weld

D4.46 -Weld force

D4.47 -Travel speed

D4.48 -Tool tilt angle

D4.49 -Weld spindal speed

Weld termination

D4.50 -Exit motion of tool such as tilt angle rotation

D4.51 -Spindal speed at tool extraction

D4.52 -Dwell at end of travel

Page 174: Supplier Evaluation (QVR)Rev6 0112

FBW RBW

D4.53 Electrode design-eliminate die burns

D4.54 Electrode/Die cleanliness

D4.55 Electrode/Die clamping pressure

D4.56 Part cleanliness and scale removal

D4.57 Part alignment

D4.58 Joint geometry preporation

D4.59 Initial martial stickout or extension beyond electrodes

Preheat

D4.60 -Preheat force

D4.61 -Tap selection

D4.62 -Percent heat

D4.63 -Off time during initial die opening

Initial Flashing

D4.64 -Initial die opening

D4.65 -Initial flashing rate

D4.66 -Type of platten movement (linear or parabolic)

D4.67 -Voltage

D4.68 -Initial flashing distance or time

D4.69 -Percent heat

D4.70 -Tap selection

Flashing

D4.71 -Flashing rate

D4.72 -Type of platten movement (linear or parabolic)

D4.73 -Voltage

D4.74 -Flashing distance or time

D4.75 -Percent heat

D4.76 -Tap selection

Weld Stage 1

D4.77 -Percent heat

D4.78 -Tap selection voltage

D4.79 -Force

D4.80 -Pulsation (on, off and number of pulses)

D4.81 -Off time before stage change

Weld Stage 2 (can be multiple stages with different parameters)

D4.82 -Percent heat

D4.83 -Tap selection voltage

D4.84 -Force

D4.85 -Pulsation (on, off and number of pulses)

Forge/Upset

Page 175: Supplier Evaluation (QVR)Rev6 0112

D4.86 -Forge rate

D4.87 -Forge force

D4.88 -Forge distance / total upset

D4.89 -Upset time

D4.90 -Upset current

D4.91 -Flashing voltage cut off

D4.92 -Flashing removal / management

Post weld heat treatment if needed

D4.93 -Heat treatment clamping distance

D4.94 -Quench time

D4.95 -Tap selection

D4.96 -Precent heat

D4.97 -Temper time

D4.98 Final die opening

Ultrasonic Metal weldD4.99 Tap selection / design of ribbon structure

D4.100 Frequency of power supply for application (40/30/20kHz)

D4.101 Fixture & part design with max dimension deviation and material specsUpset and Monitoring (windowing)

D4.102 Welding-Energy

D4.103 Welding-Time

D4.104 Welding-Amplitude

D4.105 Welding-Force

D4.106 Welding-Current

D4.107 Welding pre Height and travel (compaction)

D4.108 Energy with height compensation

D4.109 Weld Head Cooling

D4.110 Environmental conditions control (i.e., temperature, humidity, dust, etc.)

D4.111 TAP/Die cleanliness

D4.112 TAP/Die clamping pressure

D4.113 Part cleanliness and scale removal

D4.114 Part alignment

© 2010 Automotive Industry Action Group (AIAG)

x1: If required to achieve heat balance. Example thin part to thick part or various hardnesses.

Page 176: Supplier Evaluation (QVR)Rev6 0112

X X X

X X X

X X X

X X X

X

X X X

X

X X X

X X X

X X

X X

X X

X X

X X

X X

- Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the

Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor

X indicates an essential variable which shall be documented and controlled. indicates that procedure should be reviewed and documented when necessary.

Inertia Friction Welding (FRW-I)

Direct Drive Friction Welding

(FRW-DD)

Friction Stir

Welding (FSW)

Flash Butt Welding

(FW)

Resistance Butt

Welding (UW)

Ultrasonic Welding

X1 X1

X1 X1

X1 X1

X1

Cover PageCover Page Index PageIndex Page

Page 177: Supplier Evaluation (QVR)Rev6 0112

X

X

X

X

X X

X X

X X

X

X

X

X

X

ü ü ü

ü

XX X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Page 178: Supplier Evaluation (QVR)Rev6 0112

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Weld Stage 2 (can be multiple stages with different parameters)

X

X

X

X

Page 179: Supplier Evaluation (QVR)Rev6 0112

X X

X X

X X

X X

X X

X

X X

ü ü

ü ü

ü ü

ü ü

ü ü

X X

üü

Fixture & part design with max dimension deviation and material specs ü

X

X

X

X

X

X

Environmental conditions control (i.e., temperature, humidity, dust, etc.) üüüüü

: If required to achieve heat balance. Example thin part to thick part or various hardnesses.

Page 180: Supplier Evaluation (QVR)Rev6 0112

CQI-17 SOLDERING SYSTEM ASSESSMENTInstructions for completing the Cover Sheet

1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and SolderingSpecialist) or different management system, then these locations shall be considered as separate facilities.

2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.

3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.

4 Fax number: The fax number of the facility.

5 Number of Soldering Employees at this Facility: The number of employees, salaried and hourly, associated with the soldering operation at this facility.

6 Captive Solder (Y/N): Enter "Y" if this facility solders components for their own company. Enter"N" if the company does not solder any components for their own company.

7 Commercial Solder (Y/N): Enter "Y" if this facility solders components for companies other thantheir own company. Enter "N" if this facility does not solder any components for other companies.

8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.

9 Date of Previous Assessment: List the date of the previous CQI-17 Special Process: SolderingSystem Assessment of this facility.

10 Type(s) of Soldering at this Facility: Place a checkmark to designate the soldering process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the SolderingSystem Assessment.

11 Current Quality Certification(s): the solderer shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.

12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the solderer shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.

13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the solderer's organization.

Page 181: Supplier Evaluation (QVR)Rev6 0112

14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).

15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.

16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.

17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.

Page 182: Supplier Evaluation (QVR)Rev6 0112

CQI-17 SOLDERING SYSTEM ASSESSMENT

Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and SolderingSpecialist) or different management system, then these locations shall be considered as separate facilities.

Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.

Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.

Fax number: The fax number of the facility.

Number of Soldering Employees at this Facility: The number of employees, salaried and hourly, associated with the soldering operation at this facility.

Captive Solder (Y/N): Enter "Y" if this facility solders components for their own company. Enter"N" if the company does not solder any components for their own company.

Commercial Solder (Y/N): Enter "Y" if this facility solders components for companies other thantheir own company. Enter "N" if this facility does not solder any components for other companies.Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.

Date of Previous Assessment: List the date of the previous CQI-17 Special Process: SolderingSystem Assessment of this facility.

Type(s) of Soldering at this Facility: Place a checkmark to designate the soldering process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the SolderingSystem Assessment.

Current Quality Certification(s): the solderer shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.

Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the solderer shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.

Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the solderer's organization.

Cover PageCover Page Index PageIndex Page

Page 183: Supplier Evaluation (QVR)Rev6 0112

Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).

Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.

Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.

Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.

Page 184: Supplier Evaluation (QVR)Rev6 0112

Special Process: Soldering System Assessment

Facility Name:Address

Phone NumberFax Number

Number of Soldering Employees at this Facility:

Captive Soldering Organization (Y/N)

Commercial Soldering Organization (Y/N)

Current Quality Certification(s)

Date of Re-assessment (if necessary):Personnel Contacted:Name Title

0 00 00 00 0

Auditors/AssessorsName Company

0000

Number of "Not Satisfactory" Findings

Date of Assessment:

Date of Previous Assessment:

Page 185: Supplier Evaluation (QVR)Rev6 0112

Number of "Needs Immediate Action" Findings

Number of "Fail" Findings in the Job Audit(s)

© 2010 Automortive Industry Action Group (AIAG)

Page 186: Supplier Evaluation (QVR)Rev6 0112

Special Process: Soldering System Assessment

Address

Type(s) of Soldering at this Facility:Process Table A - Process Table K -

Process Table B - Process Table L -

Process Table C - Process Table M -

Process Table D - Process Table N -

Process Table E - Process Table O -

Process Table F - Process Table P -

Process Table G - Process Table Q -

Process Table H - Process Table R -

Process Table I - Process Table S -

Process Table J -

Personnel Contacted:Phone Email

Auditors/AssessorsPhone Email

Cover PageCover Page Index PageIndex Page

Page 187: Supplier Evaluation (QVR)Rev6 0112
Page 188: Supplier Evaluation (QVR)Rev6 0112

Special Process: Soldering Process Assessment (General Facility Overview)

Question Requirements and Guidance

Section 1 - Management Responsibility and Quality Planning

1.1

1.2

1.3

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group

are registered service marks of the Automotive Industry Action Group.

Question Number

Is there a dedicated and qualified soldering expert on-

site?

To ensure readily available expertise, there shall be a dedicated and qualified soldering expert on site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including metallurgical and soldering knowledge. The qualifications shall include a minimum of 5 years experience in soldering operations or a combination of a minimum of 5 years of formal metallurgical education and soldering experience.

Does the soldering organization perform

advanced quality planning?

The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The soldering organization shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.

Are soldering FMEA's up to date and reflecting current

processing?

The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEA's are updated to reflect current part quality status.The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key soldering process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.

Page 189: Supplier Evaluation (QVR)Rev6 0112

1.4

1.5

Are soldering process control plans up to date and reflecting

current processing?

The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls.The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key solder process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEA's. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables.

Are all soldering related and referenced specifications current and available? For example: IPC, SAE, AIAG, ASTM, General Motors, Honda, Ford, and Chrysler.

To ensure all customer requirements are both understood and satisfied, the organization shall have all related solder and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by IPC, SAE, AIAG, ASTM, General Motors, Honda, Ford, and Chrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards / specifications and changes based on customer-required schedule. Timely review should be as soon as possible and shall not exceed two working weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks.

Page 190: Supplier Evaluation (QVR)Rev6 0112

1.6

1.7

1.8

Is there a written process specification for all active

processes?

The solder organization shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, atmosphere or gas flow settings, belt speeds, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control.

These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.

Has a valid process capability study been performed initially and after process equipment has been relocated, or had a

major rebuild?

To demonstrate each process is capable of yielding acceptable product the organization shall perform process capability studies for the initial validation of each process, after relocation of any process equipment, & after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial process capability studies shall be conducted for all solder processes per manufacturing line defined in scope of work & in accordance with customer requirements. A manufacturing line may include a combination of equipment that is integrated in the performance of a solder process, e.g., printing, placement, and reflow. Capability study techniques shall be appropriate for the solder product characteristics, e.g., paste height and thermal profiling. Any specific customer requirements shall be met, in the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to followed in case capability indices fall outside customer requirements or established ranges.

Does the solder organization collect and analyze data over time, and react to this data?

The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time.Methods of analysis shall include ongoing trend or historical data analysis of product or process parameters. The organization shall determine which parameters to include in such analysis.

Page 191: Supplier Evaluation (QVR)Rev6 0112

1.9

1.10

1.11

1.12

1.13

1.14

Is management reviewing the soldering process data every

24 hours?

Management shall review the soldering process data at intervals not to exceed 24 hours. The soldering process data includes but is not limited to thermal profiles, SPC, set up sheets and maintenance logs, through-put, etc.The management review shall include efforts to detect out-of-control conditions or alarm conditions. The process of reviewing the soldering process data shall be documented and this requirement also applies to computerized data.

Are internal assessments being completed on an annual

basis, at a minimum, using AIAG SSA?

The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG SSA.

Is there a system in place to authorize rework or repair and

is it documented?

The quality management system shall include a documented process for rework and repair that shall include authorization from a designated individual, a recognized team of experts, or customer requirement. The rework and repair procedures shall describe product characteristics for which rework and repair is allowed as well as those characteristics for which rework is not permissible.Any rework or repair activity shall require a processing control sheet issued by qualified technical personnel denoting the necessary solder rework or repair. Records shall clearly indicate when and how any material has been reworked or repair. Repaired parts shall meet inspection standards, and must be verified by a secondary process such as in-circuit test.

Does the Quality Department review, address, and

document customer and internal concerns?

The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.

Is there a continual improvement plan applicable

to each process defined in the scope of the assessment?

The solder organization shall define a process for continual improvement for each solder process identified in the scope of the SSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.

Does the Quality Manager or designee authorize the

disposition of material from quarantine status?

The Quality Manager is responsible for authorizing and documenting appropriate personnel to disposition quarantine material, such as components that are out of tolerance.

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1.15

1.16

1.17

1.18

Are there procedures or work instructions available to the solder personnel that define

the soldering process?

There shall be procedures or work instructions available to soldering personnel covering the soldering process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.

Is management providing employee training for

soldering?

The organization shall provide employee training for all soldering operations. All employees associated with the soldering process, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.

Is there a responsibility matrix to ensure that all key

management and supervisory functions are performed by

qualified personnel?

The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.

Is there a preventive maintenance program? Is maintenance data being

utilized to form a predictive maintenance program?

The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner.Company data, e.g., downtime, quality rejects, first-time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Furnaces and generators shall be scheduled for burn-out at frequencies determined by the organization. Maintenance data shall be collected and analyzed as part of a predictive maintenance program.

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1.19

Section 2 - Floor and Material Handling Responsibility

2.1

2.2

2.3

2.4

Has the soldering organization developed a

critical spare part list and are the parts available to minimize

production disruptions?

The soldering organization shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.

Does the facility ensure that the data entered in the receiving system matches the information on the customer's shipping documents?

Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. The facility shall have a detailed process in place to resolve receiving discrepancies.

Is product clearly identified and staged throughout the manufacturing soldering process?

Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the soldering process. Unsoldered product, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.

Is lot traceability and integrity maintained throughout all processes?

Out-going lot(s) shall be traceable to the incoming lot(s). The discipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.Traceability should include bulk packed components used for manual insertion processes.

Are procedures adequate to prevent movement of non-conforming product/material into the production system?

The control of suspect or non-conforming product/material is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification and tracking of material flow in and out of hold area. Non-conforming hold area shall be clearly designated to maintain segregation of such material. The soldering organization shall have documented procedures to identify and segregate improperly soldered parts for each process/equipment resulting from equipment failures/e-stop/loss of power.

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2.6

2.7

2.8

2.9

2.10

2.11

Are containers free of inappropriate material?

Containers handling customer product shall be free of inappropriate material. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming soldered parts or inappropriate material contaminate the finished lot.

Is part loading specified, documented and controlled?

Loading parameters shall be specified, documented and controlled. Examples include parts per rack and load size.

Are operators trained in material handling, containment action and product segregation in the event of an equipment emergency including power failure?

Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment/reaction plans related to all elements of the process. Evidence shall exist showing disposition and traceability of affected product.

Is the handling, storage and packaging adequate to preserve product quality?

The soldering organization loading/unloading systems, in process handling and shipping process shall be assessed for risk of part damage or other quality concerns for proper ESD prevention and detection (example proper operator ESD protection, work station and storage grounding). Also all material storage must meet supplier recommendation (example humidity, temperature and expiration date).

Are plant cleanliness, housekeeping, environmental and safe working conditions conducive to control and improved quality?

Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality. The soldering organization shall evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for the following items: loose parts on floor; spillage around tanks; overall plant lighting; fumes, temperature and humidity controlled per customer expectation.

Are process control parameters monitored per frequencies specified in Process Tables?

Process control parameters shall be monitored per frequencies specified in Process Tables. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log.

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2.12

2.13

2.14

© 2010 Automortive Industry Action Group (AIAG)

Are out of control/specification parameters reviewed and reacted to?

Are there documented reaction plans to both out of control and out of tolerance process parameters? Is there documented evidence that reaction plans are followed?

Are In-Process / Final Test Frequencies performed as specified in Process Tables?

In-Process / Final Test Frequencies shall be performed as specified for critical/function characteristics identified in Process Tables. Refer to Process Tables.

Is product test equipment verified?

Test equipment shall be verified/calibrated per applicable customer specific standard or per an applicable consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.

Refer to Process Tables for frequency of checks.

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Special Process: Soldering Process Assessment (General Facility Overview)

Assessment

Objective Evidence N/A Satisfactory

Section 1 - Management Responsibility and Quality Planning

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group

are registered service marks of the Automotive Industry Action Group.

Not Satisfactory

Needs Immediate Action

Cover PageCover Page Index PageIndex Page

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Section 2 - Floor and Material Handling Responsibility

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Special Process: Soldering Process Assessment (Equipment)

Question

Section 3 - Equipment

3.1

3.2

3.3

3.4

3.5

3.6

3.7

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil

penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

Question Number

Requirements and Guidance

Does each stage of the soldering operation have proper process controls?

Refer to Process Tables for requirements.

Are process and testing equipment calibrations and/or verification certified, posted, and current?

A system shall be used by the soldering facility to track calibration dates of equipment. This system will typically be a computerized tracking system or other notification system. Test equipment shall be verified/calibrated per applicable customer specific standard or consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.

Are PCB magazines, screen printer stencils, solder pallets, and other tooling maintained?

Supplier shall have preventative maintenance system that is documented and implemented.

Are thermal profile requirements of soldering operations being monitored?

Supplier shall have adequate temperature controls ensuring that PCB assemblies are only exposed to temperatures within the thermal requirements of components.

For re-flow ovens and preheating zones for wave soldering, are temperature monitoring devices checked and/or replaced regularly?

Supplier shall have preventative maintenance system that is documented and implemented.

Do you have a process to monitor your regulatory requirements and safety of your employees?

Supplier shall have implemented and documented evidence of regulatory requirements and safety.

Is manual soldering and/or re-work equipment calibrated?

Supplier shall have set-up parameters and calibration routines documented and established.

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3.8

3.9

Is there post soldering inspection station?

Supplier shall have inspection method to evaluate solder quality and feedback to previous process.

Are ESD or EOS equipment standards established?

All equipment shall be properly grounded.

© 2010 Automortive Industry Action Group (AIAG)

Page 206: Supplier Evaluation (QVR)Rev6 0112

Special Process: Soldering Process Assessment (Equipment)

Assessment

Objective Evidence N/A Satisfactory Not Satisfactory

Section 3 - Equipment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil

penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

Needs Immediate Action

Cover PageCover Page Index PageIndex Page

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Section 4 - Job Audit

This section includes final product and final product assembly and packaging

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Material:

Soldering Requirements:

Job Audit Question

4.1

4.2 1.5

4.3

4.4

4.5

4.6

4.7

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive

Industry Action Group are registered service marks of the Automotive Industry Action Group.

Question #

RelatedSSA Question #

Customer or Internal Requirement

Are contract review, advance quality planning, FMEA, control plans, etc., performed by qualified individuals?

1.21.31.4

1.17

Does the solder organization have the proper customer specifications for the part?

Does the soldering organization have a confirmation method to ensure correct parts and components are installed per customer requirements?

1.62.1

Is material identification (part numbers, lot numbers, contract numbers, etc.) and process sequencing (repair, rework, etc.) traceable to the part throughout the soldering process?

2.22.32.4

Is there documented evidence of a material certification with final inspection?

Are final packaging requirements indentified per customer specifications?

1.62.72.9

Is the proper procedure or process specification used for the soldering process? Refer to Process Tables for specific parameters. List parameters that were verified in this audit in the spaces provided below.

1.51.62.1

2.112.13

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4.8 2.13

Functional?

Dimensional?

Acceptability?

4.8.1 Requirement: Functional TestTest Method:Test frequency or quantity:Selection of samples:Specification:

4.8.2

Test Method:Test frequency or quantity:Selection of samples:Specification:

4.8.3

Test Method:Test frequency or quantity:Selection of samples:Specification:

4.8.4 Requirement: Illumination TestTest Method:Test frequency or quantity:Selection of samples:Specification:

4.8.5 Requirement: In-Circuit TestTest Method:Test frequency or quantity:Selection of samples:Specification:

4.8.6

Test Method:Test frequency or quantity:Selection of samples:Specification:

Note: Section 4.8.7 - 4.8.12 Reserved for Auditor Observations4.8.7 Requirement:

Test Method:Test frequency or quantity:Selection of samples:

What are the product inspection requirements?

Each part may have one or more requirements determined by the soldering specification. Parts must meet each requirement. List each requirement below and validate.

Requirement: Dimensional Requirements

Requirement: Environmental Test

Requirement: Conformal Coating Conformation

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Specification:4.8.8 Requirement:

Test Method:Test frequency or quantity:Selection of samples:Specification:

4.8.9 Requirement: Test Method:Test frequency or quantity:Selection of samples:Specification:

4.8.10 Requirement: Test Method:Test frequency or quantity:Selection of samples:Specification:

4.8.11 Requirement: Test Method:Test frequency or quantity:Selection of samples:Specification:

4.8.12 Requirement:Test Method:Test frequency or quantity:Selection of samples:Specification:

Operator or Inspector Responsibilities

4.9

4.10 2.9

4.11

4.12

4.13

4.14

4.15 1.17

Were appropriate process steps signed off?

1.42.22.3

2.11

Are ESD preventive methods applied (i.e., operator apparel) and functionally verified?

Were all inspection steps, as documented in the control plan performed?

1.21.4

Were steps/operations performed that were not documented in the control plan?

1.21.41.6

If additional steps were performed, were they authorized?

1.21.41.6

1.111.17

If the order was certified, did the certification accurately reflect the process performed?

2.112.13

Was the certification signed by an authorized individual?

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4.16 2.6

Packaging Requirements

4.17 2.9

4.18 2.9

Shipping Requirements

4.19 2.3

4.20

© 2010 Automortive Industry Action Group (AIAG)

Are the parts and containers free of foreign objects or contamination?

Are packaging requirements identified?

Are parts packaged to minimize mixed parts (parts packed over height of container)?

Were the parts properly identified?

Were the containers properly labeled?

2.32.9

Page 212: Supplier Evaluation (QVR)Rev6 0112

Actual Condition (Objective Evidence)

N/A

N/A

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive

Industry Action Group are registered service marks of the Automotive Industry Action Group.

Job (Shop) Order or Reference Documentation Requirement

Pass / Fail / N/A

Cover PageCover Page Index PageIndex Page

Page 213: Supplier Evaluation (QVR)Rev6 0112

Each part may have one or more requirements determined by the soldering specification. Parts must meet each requirement. List each requirement below and validate.

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Operator or Inspector Responsibilities

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ITEM # Category/Process Steps Control

1.0

1.1 1.6 Lint Free Cloth Per Spec

1.2 Replacement Frequency Per Control Plan

1.3 1.6 Proper Cleaning Area Per Product Spec

1.4 1.16 Proper Operator Handling Operator Training

2.0 Material Handling

2.1

2.2-2.9

2.1.1 Correct Material Bar Code or Manual

2.1.2 Expiration Date/Lot Control Bar Code or Manual

2.1.3 Properly Mixed Manual

2.1.4 Stabilize to Operation Temperature Bar Code or Manual

2.1.5 Open Container Disposition Bar Code / Check list

2.1.6 Excess solder paste run-out management

2.2

2.2.1 Correct Material Bar Code or Manual

2.2.2 Expiration Date/Lot Control Bar Code or Manual

2.2.3 Environmental Control (exposure) Bar Code or Manual

2.2.4 Contamination Control Work Instruction

2.2.5 Orientation Automatic or Manual

3.0

3.0.1 1.18 Preventive Maintenance (PM) Cleaning PM schedule

3.0.2 Stencil separation speed Automatic

PROCESS TABLE A - Solder Paste Printing

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Printed Wiring Board Cleaning (Dry Wipe)

Paste:Size,Volume,Container:Paste Supplier:

Manual remix / discard

Printed Wiring Board (PWB)Board Supplier:

1.42.112.12

Solder Paste EquipmentType:Equipment Supplier:

Page 217: Supplier Evaluation (QVR)Rev6 0112

3.1

3.1.1 Correct Stencil Bar Code or Manual

3.1.2

3.1.3

3.1.4 3.3 Life Cycle Date Bar Code or Manual

3.1.5 Stencil Alignment Accuracy to Machine Automatic or Manual

3.2 PWB Registration to Stencil

3.2.1 Proper Alignment Automatic

3.2.2 PWB Securing Automatic

3.3

3.3.1 1.6 Squeegee Material Compatibility with Solder Past Design Spec

3.3.2 Correct Squeegee Manual

3.3.3 In process (underside wipe) cleaning Manual or Automatic

3.3.4 Pressure of Squeegee Manual or Automatic

3.3.5 Angle of Squeegee Manual or Automatic

3.3.6 Squeegee Speed Manual or Automatic

3.3.7 Squeegee Stroke Manual or Automatic

3.3.8 1.18 Preventive Maintenance Cleaning/Replace PM schedule

3.4 Pro Flow Cartridge

3.4.1 Solder Flow Pressure Automatic

3.4.2 Correct Cartridge (Pb or Pb Free) Bar Code or Manual

3.4.3 Angle of Cartridge Manual or Automatic

3.4.4 Cartridge Speed Manual or Automatic

3.4.5 Cartridge Stroke Manual or Automatic

3.4.6 1.18 Preventive Maintenance Cleaning PM schedule

4.0 Post Print Inspection

4.1 Method Manual or Automatic

4.2 Frequency Manual

4.3 Reaction of Defects Per Process Controls

Stencil ControlSupplier:Manufacturing Method:Thickness:

In process Bottom Side CleaningType of Cleaning Method:Chemical(s) Used:Frequency:

Automatic or Manual

1.183.3

Preventive Maintenance CleaningType:Chemical(s) Used:Frequency:Confirmation method:

Automatic or Manual

SqueegeeType:Shape:Hardness:Material:

1.42.112.12

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4.4 1.6 Proper solder paste height Per Product Spec

4.5 1.6 Proper solder pad coverage Per Product Spec

5.0 Abnormal Condition Reaction

5.1 2.8 Power failure reaction plan Control plan

5.2 2.8 Emergency-stop reaction plan Control plan

5.3 2.8 Part jam reaction plan Control plan

5.4 2.8 Drop part reaction plan Control plan

5.5 2.8 In-Process Delay Reaction Plan Control plan

5.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

1.42.112.12

Based on IPC-7711, 7721

Page 219: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

Quality Audit

Quality Audit

Operator Certification

Continuous

Continuous

Continuous

Continuous

Continuous

Per Control Plan

Lot (first and last piece)

Lot (first and last piece)

Lot

Every Piece

Every Piece

PM Completion Report

Continuous

- Solder Paste Printing

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 220: Supplier Evaluation (QVR)Rev6 0112

Every Change Over

Continuous

Start up or Change Over

Continuous

Continuous

Design Review

1/shift or Change Over

Per Control Plan

1/shift or Change Over

1/shift or Change Over

1/shift or Change Over

1/shift or Change Over

PM Completion Report

1/shift or Change Over

1/shift or Change Over

1/shift or Change Over

1/shift or Change Over

1/shift or Change Over

PM Completion Report

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

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Per Control Plan

Per Control Plan

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 222: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Post Print Inspection

1.1 Manual

1.1.1 1.15, 1.16 Proper Operator training Operator Certification

1.1.2 Boundary Sample Available Good and Bad

1.1.3 Proper Magnification for pitch size Per IPC A 610

1.1.4 Proper illumination at inspection station Per IES

1.1.5 Frequency of sampling

1.2 Automatic

1.2.1 1.7 CPK

1.2.2 1.7 Boundary Sample Available

1.2.3 Calibration or verification method set Per control plan

1.2.4 Non-conforming material disposition

2.0 Post Component Placement

2.1 Automatic Vision System:

2.1.1 Calibration Standard Available

2.1.2 Part Present Yes/No

2.1.3 1.6 Orientation Per Specification

2.1.4 1.6 Polarity Per Specification

2.1.5 1.6 Skew Angle Per Specification

2.1.6 1.6 Off-centered Per Specification

2.1.7 1.6 Raised Per Specification

PROCESS TABLE B - InspectionThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

2.112.13

Per Customer Requirement

Per Customer Requirement

Good and Bad sample run at change-over and beginning of shift

1.142.4

Per Customer Requirement

1.42.112.12

Per manufacture recommendation

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2.2 Manual Inspection:

2.2.1 1.15, 1.16 Proper Operator training Operator Certification

2.2.2 Good and Bad

2.2.3 Proper Magnification for pitch size Per IPC A 610

2.2.4 Proper illumination at inspection station

2.2.5 Frequency of sampling Per control plan

2.2.6 3.9 Proper ESD protection (work surface and operator) Per ANSI S20.20

2.3 Non-conforming material disposition Per control plan

3.0 Post Reflow Inspection

3.1 Automatic Optical Inspection (AOI)

3.1.1 1.6 Solder volumes Per Specification

3.1.2 1.6 Solder ball Per Specification

3.1.3 1.6 Solder bridge Per Specification

3.1.4 1.6 Solder skip Per Specification

3.1.5 1.6 Part present Per Specification

3.1.6 1.6 Component accuracy to solder pads Per Specification

3.1.7 1.6 Tombstoning Per Specification

3.1.8 1.6 Billboarding Per Specification

3.1.9 1.6 Lifted part Per Specification

3.1.10 1.6 Good/Bad Samples Used Per Specification

3.2 X-ray (Recommended for BGA/Flip chip)

3.2.1 1.6 Solder volumes Per Specification

3.2.2 1.6 Solder ball Per Specification

3.2.3 1.6 Solder bridge Per Specification

3.2.4 1.6 Solder skip Per Specification

3.2.5 1.6 Part present Per Specification

3.2.6 1.6 Component accuracy to solder pads Per Specification

3.2.7 1.6 Tombstoning Per Specification

3.2.8 1.6 Billboarding Per Specification

3.2.9 1.6 Lifted part Per Specification

3.2.10 1.6 Void detection Per Specification

3.2.11 1.6 Good/Bad Samples Used Per Specification

3.3 Manual Inspection

3.3.1 1.6 Solder volumes Per Specification

3.3.2 1.6 Solder ball Per Specification

Boundary Sample (e.g., orientation, polarity, skew angle, off-centered, raised, and part present)

Per IES (Illumination Engineering Standard)

1.142.4

1.42.112.123.8

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3.3.3 1.6 Solder bridge Per Specification

3.3.4 1.6 Solder skip Per Specification

3.3.5 1.6 Part present Per Specification

3.3.6 1.6 Component accuracy to solder pads Per Specification

3.3.7 1.6 Tombstoning Per Specification

3.3.8 1.6 Billboarding Per Specification

3.3.9 1.6 Lifted part Per Specification

3.3.10 1.6 Void detection Per Specification

3.3.11 1.15, 1.16 Proper Operator training Operator Certification

3.3.12 Good and Bad

3.3.13 Proper Magnification for pitch size Per IPC A 610

3.3.14 Proper illumination at inspection station

3.3.15 Frequency of sampling Per control plan

3.3.16 3.9 Proper ESD protection (work surface and operator) Per ANSI S20.20

3.3.17 1.6 Blow hole detection Per Specification

3.3.18 1.6 Confirmation of jig removal Per Specification

3.4 Non-conforming material disposition Per control plan

4.0 Post Wave/Selective Solder Inspection

4.1 Automatic Optical Inspection (AOI)

4.1.1 1.6 Solder volumes Per Specification

4.1.2 1.6 Solder ball Per Specification

4.1.3 1.6 Solder bridge Per Specification

4.1.4 1.6 Solder skip Per Specification

4.1.5 1.6 Part present Per Specification

4.1.6 1.6 Component accuracy to solder pads Per Specification

4.1.7 1.6 Tombstoning Per Specification

4.1.8 1.6 Billboarding Per Specification

4.1.9 1.6 SMT Glue on pad Per Specification

4.1.10 1.6 Lifted part Per Specification

4.1.11 1.6 Excess Flux/flux residue Per Specification

4.1.12 1.6 Proper polarity Per Specification

4.1.13 1.6 Icicling Per Specification

4.1.14 1.6 Good/Bad Samples Used Per Specification

4.2 X-ray

4.2.1 1.6 Solder volumes Per Specification

Boundary Sample (e.g., orientation, polarity, skew angle, off-centered, raised, and part present)

Per IES (Illumination Engineering Standard)

2.112.13

1.142.4

1.42.112.123.8

Page 225: Supplier Evaluation (QVR)Rev6 0112

4.2.2 1.6 Solder ball Per Specification

4.2.3 1.6 Solder bridge Per Specification

4.2.4 1.6 Solder skip Per Specification

4.2.5 1.6 Part present Per Specification

4.2.6 1.6 Component accuracy to solder pads Per Specification

4.2.7 1.6 Tombstoning Per Specification

4.2.8 1.6 Billboarding Per Specification

4.2.9 1.6 Lifted part Per Specification

4.2.10 1.6 Void detection Per Specification

4.2.11 1.6 Icicling Per Specification

4.2.12 1.6 Good/Bad Samples Used Per Specification

4.3 Manual Inspection

4.3.1 1.6 Solder volumes Per Specification

4.3.2 1.6 Solder ball Per Specification

4.3.3 1.6 Solder bridge Per Specification

4.3.4 1.6 Solder skip Per Specification

4.3.5 1.6 Part present Per Specification

4.3.6 1.6 Component accuracy to solder pads Per Specification

4.3.7 1.6 Tombstoning Per Specification

4.3.8 1.6 Billboarding Per Specification

4.3.9 1.6 Lifted part Per Specification

4.3.10 1.6 Void detection Per Specification

4.3.11 1.16 Proper Operator training Operator Certification

4.3.12 Good and Bad

4.3.13 Proper Magnification for pitch size

4.3.14 Proper illumination at inspection station

4.3.15 2.13 Frequency of sampling Per control plan

4.3.16 3.9 Proper ESD protection (work surface and operator) Per ANSI S20.20

4.3.17 Blow hole detection

4.3.18 1.6 Icicling Per Specification

4.3.19 1.6 Excess Flux/flux residue Per Specification

4.3.20 1.6 SMT Glue on pad Per Specification

4.3.21 1.6 Confirmation of jig removal Per Specification

Boundary Sample (e.g., orientation, polarity, skew angle, off-centered, raised, and part present) as needed.

Per IPC A 610 or organizations internal requirements

Per IES (Illumination Engineering Standard) or organizations internal requirements

Page 226: Supplier Evaluation (QVR)Rev6 0112

4.3.22 1.6 No foreign material Per Specification

4.3.23 1.6 Trace delamination Per Specification

4.3.24 1.6 Solder mask degradation Per Specification

4.4 Non-conforming material deposition Per control plan

© 2010 Automortive Industry Action Group (AIAG)

1.142.4

Page 227: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Annual Certification

Calibration Certification

Annual Certification

Set-up

Check-sheet

Continuous

Calibration Certification

Calibration Certification

Continuous

Calibration Certification

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

- InspectionThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 228: Supplier Evaluation (QVR)Rev6 0112

Annual Certification

Calibration Certification

Annual Certification

Set-up

Check-sheet

Continuous

Continuous

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Page 229: Supplier Evaluation (QVR)Rev6 0112

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Annual Certification

Calibration Certification

Annual Certification

Set-up

Check-sheet

Continuous

Per Control Plan

Per Control Plan

Continuous

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Page 230: Supplier Evaluation (QVR)Rev6 0112

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Annual Certification

Calibration Certification

Annual Certification

Set-up

Check-sheet

Continuous

Per Control Plan

Per Control Plan

Per Control Plan

Per Control Plan

Page 231: Supplier Evaluation (QVR)Rev6 0112

Per Control Plan

Per Control Plan

Per Control Plan

Continuous

Page 232: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Cassette/Feeder Loading

1.1 Manual Control

1.1.1 1.15, 1.16 Correct loading Operator Training

1.1.2 3.9 ESD Control Per ANSI S20.20

1.1.3 Correct Part per Feeder Location Set-up Sheet

1.1.4 Operator/Traceability Control Check Sheet

1.1.5 Check Sheet

1.1.6 Humidity (MSD) Control

1.2 Automatic Control

1.2.1 1.15, 1.16 Correct loading Operator Training

1.2.2 3.9 ESD Control Per ANSI S20.20

1.2.3 Correct Part per Feeder Location Bar Code and BOM

1.2.4 Operator/Traceability Control Bar Code Scan

1.2.5

1.2.6 Humidity (MSD) Control Per control plan

2.0 Splicing

2.1 1.15, 1.16 Correct Splicing Operator Training

2.2 3.9 ESD Control Per ANSI S20.20

2.3 1.6 Correct Orientation Per Machine Spec

2.4 Traceability Control

2.5 Humidity Control Per control plan

2.6 1.6 Correct Tape Per Spec

PROCESS TABLE C - Surface Mount Device PlacementThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Component supply management (part shortage prevention)

1.62.10

Per Manufacturer Spec

Component supply management (part shortage prevention)

Machine Programming (Placement Count)

1.62.10

1.42.112.12

Check Sheet/Bar Code

1.62.10

Page 233: Supplier Evaluation (QVR)Rev6 0112

2.7 Correct Splice Operator Training

3.0 Placement Nozzles

3.1 Manual Operation

3.1.1 1.15, 1.16 Correct nozzle selection Operator Training

3.1.2 Vacuum testing Per check sheet

3.1.3 Correct placement stroke & force Per set up sheet

3.1.4 Trigger for First Pass Yield (FPY) Maintenance Per control plan

3.2 Automatic Operation

3.2.1 1.15, 1.16 Correct magazine carrousel loading Operator Training

3.2.2 Correct placement program Per control plan

3.2.3 Initial nozzle vacuum confirmation Per program

3.2.4 Trigger for FPY Maintenance Per control plan

4.0 Vision System

4.1 1.15, 1.16 Proper set up Operator Training

4.2 Per control plan

4.3 1.6 Proper focusing Per product spec

4.4 Proper illumination Per requirement

4.5 Correct operation Per golden sample

4.6 Calibration Per NIST

5.0 Bottom Side Placement

5.1 Must adhered to Items 1.0 - 4.6 above

5.2 Board flex (if top side soldered) Per IPC-A-610

6.0 Abnormal Condition Reaction

6.1 2.8 Power failure reaction plan Control plan

6.2 2.8 Emergency-stop reaction plan Control plan

6.3 2.8 Part jam reaction plan Control plan

6.4 2.8 Drop part reaction plan Control plan

6.5 2.8 In Process Delay Reaction Plan Control plan

6.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

1.42.112.12

1.42.112.12

Proper inspection criteria (placement accuracy, polarity, rotation/skewing)

1.42.112.12

1.42.112.12

Based on IPC-7711, 7721

Page 234: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Per Training Plan

Continuous

Supervisor Audit

100%

Per Control Plan

Per Control Plan

Per Training Plan

Continuous

100%

100%

Continuous

Continuous

Per Training Plan

Continuous

100%

100%

Continuous

100%

- Surface Mount Device PlacementThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 235: Supplier Evaluation (QVR)Rev6 0112

Per Training Plan

Per Training Plan

Per change over

Per change over

100%

Per Training Plan

Per change over

100%

100%

Per training plan

100%

100%

100%

Per Control Plan

Per Control Plan

Process Set-up

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 236: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Reflow ovens

1.1 3.4 Temperature controller Automatic

1.1.1 3.4 Lead Solder Correct Profile

1.1.2 3.4 Lead Free Solder Correct Profile

1.2 1.18 Heating element Proper PM

1.3 Atmosphere control Automatic

1.3.1 Ventilation Automatic

1.3.2 Nitrogen supply system (if used) Automatic

1.3.3 Oxygen monitoring system (if used) Automatic

1.4 Conveyer width control Per set-up

1.5 Conveyer speed control

1.6 Conveyer infeed cover In place

1.7 3.5 M.O.L.E. / Surveyor

1.7.1 3.5 Thermal couple board placement

1.7.2 3.5 K.I.C. system (if used) Automatic

1.7.3 Profile confirmation verification Per control plan

1.7.4 Process Window (PWI)/Capability Index Per control plan

1.8 3.9 ESD Control Per ANSI S20.20

1.9 Lead/Lead free changeovers Proper oven cleaning

2.0 Loading

2.1 Correct Orientation

2.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training

PROCESS TABLE D - Reflow Soldering Process

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Automatic per Control Plan

Based on board layout

3.43.5

3.43.5

1.42.112.12

Automatic/operator training

Page 237: Supplier Evaluation (QVR)Rev6 0112

2.3 Correct Spacing

2.4 1.15, 1.16 Proper placement in pallet (if used) Operator Training

3.0 Unloading

3.1 3.9 ESD Control Per ANSI S20.20

3.2 1.15, 1.16 Proper Handling Operator Training

3.3 Cooling/Ion Blowers

3.3.1 Filters presence Per control plan

3.3.2 Proper location on conveyor Per spec/set-up

3.3.3 Blower/ionizer power-on indicator Per control plan

3.4 3.3 Magazines / Unloading racks

3.4.1 Correct Type for product (Pb/Pb free) Per control plan

3.4.2 Correct width and height for product Per control plan

3.4.3 Per control plan

3.4.4 Covered for transportation and storage Per control plan

3.5 1.14 Written policy

4.0 Component Compatibility

4.1 1.6 Components compatible with temperature profile Component Spec

4.2 1.6 Components compatible with solder Component Spec

5.0 Board Twist Control

5.1 Maximum diagonal twist meets standard

6.0 Abnormal Condition Reaction

6.1 2.8 Power failure reaction plan Control plan

6.2 2.8 Emergency-stop reaction plan Control plan

6.3 2.8 Part jam reaction plan Control plan

6.4 2.8 Drop part reaction plan Control plan

6.5 2.8 In Process Delay Reaction Plan Control plan

6.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

Automatic/operator training

1.42.112.12

Correct loading sequence for contamination control (top down)

Rejected / inspected part returned to production line and inserted at the removal point.

1.42.112.12

1.42.112.12

Per IPC-TM-650, Section 2.4.22

1.42.112.12

Based on IPC-7711, 7721

Page 238: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

Continuous

Continuous

PM Completion Report

Continuous

Continuous

Continuous

Continuous

Per control plan

Continuous

Continuous

Per control plan

Continuous

Per control plan

Per control plan

Continuous

Continuous

Continuous

- Reflow Soldering Process

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Per control plan/changeover

Cover PageCover Page Index PageIndex Page

Page 239: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Daily Check Sheet

Daily Check Sheet

Continuous

Continuous

Continuous

Continuous

Control Plan

Design Review

Design Review

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Per Preventative Maintenance

Changeover/profile modification

Page 240: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0

1.1 Correct Material Bar Code or Manual

1.2 Expiration Date/Lot Control Bar Code or Manual

1.3 Properly Mixed Manual

1.4 Stabilize to Operation Temperature Bar Code or Manual

1.5 Open Container Disposition Control plan

2.0 Glue Dispensing Equipment

2.1 Pin Transfer:

2.1.1 PWB Registration to Equipment Automatic

2.1.2 PWB Securing Automatic

2.1.3 1.18 Preventive Maintenance PM schedule

2.1.4 Stabilization and control of glue reservoir Automatic/Manual

2.2

2.2.1 PWB Registration to Equipment Automatic

2.2.2 PWB Securing Automatic

2.2.3 3.3 Correct Stencil Bar Code or Manual

2.3

2.3.1 Type of Cleaning Method Automatic or Manual

2.3.2 Frequency Automatic or Manual

2.4 1.18 PM schedule

2.5 Life Cycle Date Bar Code or Manual

2.6 Stencil Alignment Accuracy to Machine Automatic or Manual

2.7 Syringe:

2.7.1 PWB Registration to Equipment Automatic

PROCESS TABLE E - Glue Dispensing

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Glue:Supplier:Size, Volume, Container:

1.42.112.12

Screen Printing:Stencil Supplier:

In-process Bottom Side Cleaning:Chemical(s) Used:

Preventive Maintenance CleaningChemical(s) Used:Methods Used:

Page 241: Supplier Evaluation (QVR)Rev6 0112

2.7.2 PWB Securing Automatic

2.7.3 1.18 PM schedule

3.0

3.1 3.4 Correct Thermal Profile Automatic or Manual

3.2 Conveyer Speed Per Control Plan

3.3 Rail Width Per Control Plan

4.0 Post Glue Inspection

4.1 Glue Volume Per Control Plan

4.2 Glue Placement Per Control Plan

4.3 Verify Curing is Complete Per Control Plan

4.4 Glue Contamination on Component Pad Per Control Plan

5.0 Abnormal Condition Reaction

5.1 2.8 Power failure reaction plan Control plan

5.2 2.8 Emergency-stop reaction plan Control plan

5.3 2.8 Part jam reaction plan Control plan

5.4 2.8 Drop part reaction plan Control plan

5.5 2.8 In Process Delay Reaction Plan Control plan

5.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

Preventive Maintenance CleaningChemical(s) Used:Method Used:

1.42.112.12

Glue Curing ProcessEquipment type:

1.42.112.12

1.42.112.12

Based on IPC-7711, 7721

Page 242: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Every Container

Every Container

Every Container

Every Container

Continuous

Every Piece

Every Piece

PM Completion Report

Continuous

Every Piece

Every Piece

Every Change Over

Cycle

Per Control Plan

PM Completion Report

Continuous

Start up or Change Over

Every Piece

- Glue Dispensing

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 243: Supplier Evaluation (QVR)Rev6 0112

Every Piece

PM Completion Report

1/shift or Change Over

Start up or Change Over

Start up or Change Over

Per Product Spec.

Per Product Spec.

Per Product Spec.

Per Product Spec.

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 244: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Integrated Equipment

1.1 Bubble/Foam

1.1.1 Flux coverage area Sample Board

1.1.2 Exclusion zones Sample Board

1.1.3 Uniformity Sample Board

1.1.4 Via hole penetration Actual Board

1.1.5 Density of Flux/Viscosity

1.1.6 Set-up Sheet

1.1.7 1.18 Bubbler/Air Stone PM PM schedule

PROCESS TABLE F - Flux Application for Wave Soldering Process

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Flux density meter/Zahn Cup

Air KnifeLocation:Gap:Air Pressure:

Page 245: Supplier Evaluation (QVR)Rev6 0112

1.2 Spray

1.2.1 Flux coverage area

1.2.2 Exclusion zones

1.2.3 Uniformity

1.2.4 Via hole penetration Actual Bare Board

1.2.5 1.18 PM schedule

1.2.6 Automatic

2.0 Stand Alone Equipment

2.1 Bubble/Foam

2.1.1 Flux coverage area Sample Board

2.1.2 Exclusion zones Sample Board

2.1.3 Uniformity Sample Board

2.1.4 Via hole penetration Actual Board

2.1.5 Density of Flux/Viscosity

Sample Board or Glass Plate

Sample Board or Glass Plate

Sample Board or Glass Plate

Preventive Maintenance CleaningChemical(s) Used:Method Used:

Prevention of air introduction into flux lines during supply change/addiition of flux

1.42.112.12

Flux density meter/Zahn Cup

Page 246: Supplier Evaluation (QVR)Rev6 0112

2.1.6 Set-up Sheet

2.1.7 1.18 Bubbler/Air Stone PM PM schedule

2.2 Spray Correct Profile

2.2.1 Flux coverage area Sample Board

2.2.2 Exclusion zones Sample Board

2.2.3 Uniformity Sample Board

2.2.4 Via hole penetration Actual Board

2.3 2.4 Written policy

2.4 1.18 PM schedule

3.0 Manual Flux Application

3.1 Brush

3.1.1 Flux coverage area Sample Board

3.1.2 Exclusion zones Sample Board

3.1.3 Uniformity Sample Board

Air KnifeLocation:Gap:Air Pressure:

Rejected / inspected part returned to production line and inserted at the removal point.

Preventive Maintenance CleaningChemical(s) Used:Method Used:

1.42.112.12

Page 247: Supplier Evaluation (QVR)Rev6 0112

3.1.4 Via hole penetration Actual Board

3.1.5 Brush Replacement Frequency Control Plan

3.2 Dip

3.2.1 Flux coverage area Sample Part

3.2.2 Exclusion zones Sample Part

3.2.3 Uniformity Sample Part

3.2.4 Via hole penetration Sample Part

3.2.5 Flux tank volume level control Automatic / Manual

3.3 Sponge

3.3.1 Flux coverage area Sample Board

3.3.2 Exclusion zones Sample Board

3.3.3 Uniformity Sample Board

3.3.4 Via hole penetration Actual Board

3.3.5 Sponge Replacement Frequency Control Plan

Page 248: Supplier Evaluation (QVR)Rev6 0112

4.0 Loading (Integrated/Stand alone)

4.1 Correct Orientation

4.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training

4.3 Correct Spacing

4.4 1.15, 1.16 Proper placement in pallet (if used) Operator Training

4.5 3.9 ESD Control Per ANSI S20.20

4.6 1.15, 1.16 Proper Handling Operator Training

4.7 1.18 Equipment Cleanliness PM schedule

5.0 Unloading (Stand alone)

5.1 1.6 Proper location on conveyor Per spec/set-up

5.2 1.6 Conveyor width set properly Per spec/set-up

5.3 1.6 Conveyors covered Per spec/set-up

6.0 Component Compatibility

6.1 1.6 Flux Type correct for solder in use Component Spec

1.42.112.12

Automatic/operator training

Automatic/operator training

1.42.112.12

1.42.112.12

Page 249: Supplier Evaluation (QVR)Rev6 0112

6.2 Flux Type matches Bill of Material (BOM) BOM

6.3 Proper flux storage condition/environment

6.4 Proper flux for specified solder Control Plan

7.0 Abnormal Condition Reaction

7.1 2.8 Power failure reaction plan Control plan

7.2 2.8 Emergency-stop reaction plan Control plan

7.3 2.8 Part jam reaction plan Control plan

7.4 2.8 Drop part reaction plan Control plan

7.5 2.8 In-Process Delay Reaction Plan Control plan

7.6 1.11 Repair/rework procedures

8.0 Manual Flux Application Handling

8.1 3.9 ESD Control Per ANSI S20.20

8.2 1.15, 1.16 Proper Handling Operator Training

© 2010 Automortive Industry Action Group (AIAG)

Manufacturer Specification

1.42.112.12

Based on IPC-7711, 7721

1.42.112.12

Page 250: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Once per shift/change over

Once per shift/change over

Once per shift/change over

Once per shift/change over

Once per shift/change over

Once per shift/change over

PM Completion Report

Flux Application for Wave Soldering Process

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor

Cover PageCover Page Index PageIndex Page

Page 251: Supplier Evaluation (QVR)Rev6 0112

Once per shift/change over

Once per shift/change over

Once per shift/change over

PM Completion Report

Continous

Once per shift/change over

Once per shift/change over

Once per shift/change over

Once per shift/change over

Once per shift/change over

For process initial set-up or process troubleshooting only

Page 252: Supplier Evaluation (QVR)Rev6 0112

Once per shift/change over

PM Completion Report

Continuous

Once per shift/change over

Once per shift/change over

Once per shift/change over

Once per shift/change over

Control Plan

PM Completion Report

Once per shift/change over

Once per shift/change over

Once per shift/change over

Page 253: Supplier Evaluation (QVR)Rev6 0112

Once per shift/change over

Per Control Plan

Once per shift/change over

Once per shift/change over

Once per shift/change over

Once per shift/change over

Continuous / Check sheet

Once per shift/change over

Once per shift/change over

Once per shift/change over

Once per shift/change over

Per Control Plan

Page 254: Supplier Evaluation (QVR)Rev6 0112

100%

100%

100%

100%

Continous

100%

PM Completion Report

Daily Check Sheet

Daily Check Sheet

Daily Check Sheet

Design Review

Page 255: Supplier Evaluation (QVR)Rev6 0112

Daily Check Sheet

Supervisior review

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Per changeover/replenishment

Page 256: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Pre-Heat Equipment

1.1 3.4 Temperature controller Automatic

1.1.1 3.4 Lead Solder Correct Profile

1.1.2 3.4 Lead Free Solder Correct Profile

1.2 1.18 Zone Heating element Proper PM

1.3 Atmosphere control Automatic

1.3.1 Ventilation Automatic

1.3.2 Nitrogen supply system (if used) Automatic

1.3.3 Oxygen monitoring system (if used) Automatic

1.4 Conveyer

1.4.1 Conveyer width control Per set-up

1.4.2 Conveyer speed control Automatic

1.4.3 Conveyer Finger Cleaner Per control plan

1.5 Temperature Profile Verification

1.5.1 3.5 M.O.L.E. / Surveyor Per control plan

1.5.2 3.5 Thermal couple board placement Based on board layout

1.6 3.9 ESD Control Per ANSI S20.20

2.0 Loading

2.1 3.9 ESD Control Per ANSI S20.20

2.2 Correct Orientation

2.3 1.15, 1.16 Stiffeners (if used) correct placement Operator Training

2.4 Correct Spacing between Boards

2.5 1.15, 1.16 Proper board placement in pallet (if used) Operator Training

2.6 Conveyer infeed cover (if required) In place

PROCESS TABLE G - Pre-Heat for Soldering Process

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

1.42.112.12

Automatic/operator training

Automatic/operator training

Page 257: Supplier Evaluation (QVR)Rev6 0112

3.0 Transferring

3.1 3.9 ESD Control Per ANSI S20.20

3.2 1.15, 1.16 Proper Handling Operator Training

3.3 Conveyer cover (if required) In place

4.0 Component Compatibility

4.1 1.6 Components compatible with temperature profile Component Spec

5.0 Abnormal Condition Reaction

5.1 2.8 Power failure reaction plan Control plan

5.2 2.8 Emergency-stop reaction plan Control plan

5.3 2.8 Part jam reaction plan Control plan

5.4 2.8 Drop part reaction plan Control plan

5.5 2.8 In Process Delay Reaction Plan Control plan

5.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

1.42.112.12

1.42.112.12

1.42.112.12

Based on IPC-7711, 7721

Page 258: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

Continuous

Continuous

PM Completion Report

Continuous

Continuous

Continuous

Continuous

Per control plan

Continuous

Continuous

Per control plan

Per control plan

Continuous

Continuous

100%

100%

100%

100%

100%

- Pre-Heat for Soldering Process

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company.  Copyright

infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 259: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Design Review

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 260: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Equipment

1.1 Flux Application - See Process Table F

1.2 Pre-heat Process - See Process Table G

1.3 Wave Solder Machine

1.3.1 Solder Pot Temperature controller Automatic

1.3.2 Lead Solder

1.3.3 Lead Free Solder

1.3.4 1.18 Pot Heating element Proper PM

1.3.5 Atmosphere control Automatic

1.3.5.1 Ventilation Automatic

1.3.5.2 Nitrogen supply system (if used) Automatic

1.3.5.3 Oxygen monitoring system (if used) Automatic

1.3.6 Conveyer width control Per set-up

1.3.7 Conveyer speed control

1.3.8 Conveyer in-feed cover In place

1.3.9 Conveyer Finger Cleaner Per control plan

1.4 Temperature Profile Verification

1.4.1 M.O.L.E. / Surveyor Per control plan

1.4.2 Thermal couple board placement Based on board layout

1.5 Wave Height Control

1.5.1 Solder pump RPM Per control plan

1.5.2 Wave Vibrational Control (if used) Per control plan

1.5.3 Product sensor / timer

1.5.4 Solder pot level control Automatic

1.6 3.9 ESD Control Per ANSI S20.20

PROCESS TABLE H - Wave Soldering Process

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Correct Temperature Profile

Correct Temperature Profile

Automatic per Control Plan

Solder Pump Wave Control (Pump off if no product present)

Page 261: Supplier Evaluation (QVR)Rev6 0112

1.7 Lead/Lead free changeovers

1.8 1.6 Equipment lead-free compatible

1.9 Dross Removal Frequency Per control plan

2.0 Loading

2.1 3.9 ESD Control Per ANSI S20.20

2.2 Correct Orientation

2.3 1.15, 1.16 Stiffeners (if used) correct placement Operator Training

2.4 Correct Spacing between Boards

2.5 1.15, 1.16 Proper board placement in pallet (if used) Operator Training

2.6 Conveyer cover (if required) In place

3.0 Unloading

3.1 3.9 ESD Control Per ANSI S20.20

3.2 1.15, 1.16 Proper Handling Operator Training

3.3 Cooling/Ion Blowers

3.3.1 Filters presence Per control plan

3.3.2 1.6 Proper location on conveyor Per spec/set-up

3.3.3 Blower Operation indicator Per control plan

3.4 Magazines / Unloading racks

3.4.1 Correct Type for product (Pb/Pb free) Per control plan

3.4.2 Correct width and height for product Per control plan

3.4.3 Correct loading sequence (top down) Per control plan

3.4.4 Covered for transportation and storage Per control plan

3.5 Pallet Cleaning Per control plan

4.0 Component Compatibility

4.1 1.6 Components compatible with solder temperature Component Spec

4.2 1.6 Components surface finish compatible with solder Component Spec

4.3 1.6 Solder Pot Elemental Analysis Product specification

4.4 Prevention of Pb/Pb-free solder bar mix Proper error-proofing

5.0 Board Twist Control

Proper equipment cleaning

Per equipment specification

1.42.112.12

Automatic/operator training

Automatic/operator training

1.42.112.12

1.42.112.12

1.42.112.12

Page 262: Supplier Evaluation (QVR)Rev6 0112

5.1 Maximum diagonal twist meets standard

6.0 Abnormal Condition Reaction

6.1 2.8 Power failure reaction plan Control plan

6.2 2.8 Emergency-stop reaction plan Control plan

6.3 2.8 Part jam reaction plan Control plan

6.4 2.8 Drop part reaction plan Control plan

6.5 2.8 In Process Delay Reaction Plan Control plan

6.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

Per IPC-TM-650, Section 2.4.22, or per customer requirement

1.42.112.12

Based on IPC-7711, 7721

Page 263: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

Continuous

Continuous

PM Completion Report

Continuous

Continuous

Continuous

Continuous

Per control plan

Continuous

Continuous

Continuous

Per control plan

Per control plan

Continuous

Continuous

Continuous

Continuous

Continuous

- Wave Soldering Process

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 264: Supplier Evaluation (QVR)Rev6 0112

Design Review

Check sheet

Continuous

100%

100%

100%

100%

100%

Continuous

Continuous

Daily Check Sheet

Daily Check Sheet

Continuous

Continuous

Continuous

Continuous

Per Control Plan

Design Review

Design Review

100%

Per control plan/changeover

Per Preventative Maintenance

Pb-free; Quarterly Lab Results, Pb; annual lab results

Page 265: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Changeover/profile modification

Page 266: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Equipment

1.1 Flux Application See Process Table F

1.2 Pre-heat Process See Process Table G

1.3 Selective Soldering Machine

1.3.1 Solder Pot Temperature controller Automatic

1.3.2 Tin-Lead Solder Correct Temperature

1.3.3 Lead Free Solder Correct Temperature

1.3.4 1.18 Pot Heating element Proper PM

1.3.5 Atmosphere control

1.3.5.1 Ventilation Automatic

1.3.5.2 Nitrogen supply system (if used) Automatic

1.3.5.3 Oxygen monitoring system (if used) Automatic

1.3.6 Conveyer width control Per set-up

1.3.7 Conveyer index speed control

Conveyer Dwell Time

1.3.8 Conveyer infeed cover In place

1.3.9 Conveyer Finger Cleaner Per control plan

1.6 Conveyer Vertical Index Distance (if movable) Per machine spec

1.4 Temperature Profile Verification

1.4.1 M.O.L.E. / Surveyor Per control plan

1.4.2 Thermal couple board placement Based on board layout

1.5 Fountain Height Control

1.5.1 1.6 Nozzle Vertical Index Distance (if movable) Per machine spec

1.5.2 Solder pump RPM Per control plan

1.5.3 1.18 Nozzle cleanliness Proper PM

1.5.4 Solder pot level control Automatic

1.6 3.9 ESD Control Per ANSI S20.20

PROCESS TABLE I - Fountain Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Automatic per Control Plan

Automatic per Control Plan

Page 267: Supplier Evaluation (QVR)Rev6 0112

1.7 Lead/Lead free changeovers

1.8 1.6 Equipment lead-free compatible

1.9 Dross Removal Frequency from Solder Pot Per control plan

1.10 Dross Removal Frequency from Nozzle area Per control plan

2.0 Transferring

2.1 3.9 ESD Control Per ANSI S20.20

2.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training

2.3 1.15, 1.16 Correct Spacing between Boards

2.4 1.15, 1.16 Proper board placement in pallet (if used) Operator Training

2.5 Conveyer cover (if required) In place

3.0 Unloading

3.1 3.9 ESD Control Per ANSI S20.20

3.2 1.15, 1.16 Proper Handling Operator Training

3.3 Cooling/Ion Blowers

3.3.1 Filters presence Per control plan

3.3.2 1.6 Proper location on conveyor Per spec/set-up

3.3.3 Blower Operation indicator Per control plan

3.4 Magazines / Unloading racks

3.4.1 Correct Type for product (Pb/Pb free) Per control plan

3.4.2 Correct width and height for product Per control plan

3.4.3 Correct loading sequence (top down) Per control plan

3.4.4 Covered for transportation and storage Per control plan

3.4.5 Proper ESD control Per ANSI S20.20

3.5 Pallet Cleaning Per control plan

4.0 Component Compatibility

4.1 1.6 Component Spec

4.2 1.6 Components surface finish compatible with solder Component Spec

4.3 1.6 Solder Pot Elemental Analysis Product specification

4.4 Prevention of Pb/Pb-free solder bar mix Proper error-proofing

5.0 Warpage Control

Proper equipment cleaning

Per equipment specification

1.42.112.12

Automatic/operator training

1.42.112.12

1.42.112.12

Components compatible with solder / pre heat temperature

1.42.112.12

Page 268: Supplier Evaluation (QVR)Rev6 0112

5.1 Maximum diagonal warpage meets standard

6.0 Abnormal Condition Reaction

6.1 2.8 Power failure reaction plan Control plan

6.2 2.8 Emergency-stop reaction plan Control plan

6.3 2.8 Part jam reaction plan Control plan

6.4 2.8 Drop part reaction plan Control plan

6.5 2.8 In Process Delay Reaction Plan Control plan

6.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

Per IPC-TM-650, Section 2.4.22, or per customer requirement

1.42.112.12

Based on IPC-7711, 7721

Page 269: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

Continuous

Continuous

PM Completion Report

Continuous

Flow Meter

Continuous

Per control plan

Continuous

Continuous

Continuous

Continuous

Set-up Sheet

Per control plan

Per control plan

Set-up Sheet

Continuous

PM Completion Report

Continuous

Continuous

- Fountain Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 270: Supplier Evaluation (QVR)Rev6 0112

Design Review

Check sheet

As needed

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Daily Check Sheet

Daily Check Sheet

Continuous

Continuous

Continuous

Continuous

Continuous

Per Control Plan

Design Review

Design Review

100%

Per control plan/changeover

Per Preventative Maintenance

Pb-free; Quarterly Lab Results, Pb; annual lab results

Page 271: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Changeover/profile modification

Page 272: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Dip Solder Equipment

1.1 Flux Application See Process Table F

1.2 Pre-heat Process See Process Table G

1.3 Dip Soldering Machine

1.3.1 Solder Pot Temperature controller Automatic

1.3.2 Tin-Lead Solder Correct Temperature

1.3.3 Lead Free Solder Correct Temperature

1.3.4 Pot Heating element Proper PM

1.3.5 Atmosphere control

1.3.5.1 Ventilation Automatic

1.3.5.2 Nitrogen supply system (if used) Automatic

1.3.5.3 Oxygen monitoring system (if used) Automatic

1.3.6 Conveyer width control Per set-up

1.3.7 Conveyer index speed control

1.3.8 Conveyer Dwell Time

1.3.9 Conveyer Finger Cleaner Per control plan

1.3.10 Conveyer Vertical Index Distance (if movable) Per machine spec

1.4 Temperature Profile Verification

1.4.1 M.O.L.E. / Surveyor Per control plan

1.4.2 Thermal couple board placement Based on board layout

1.5.1 Solder circulation pump (if used) Per control plan

1.5.2 Solder pot level control Automatic

1.6 3.9 ESD Control Per ANSI S20.20

1.7 Lead/Lead free changeovers

1.8 1.6 Equipment lead-free compatible

PROCESS TABLE J - Dip Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Automatic per Control Plan

Automatic per Control Plan

Proper equipment cleaning

Per equipment specification

Page 273: Supplier Evaluation (QVR)Rev6 0112

1.9 Per control plan

2.0 Transferring

2.1 3.9 ESD Control Per ANSI S20.20

2.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training

2.3 1.15, 1.16 Correct Spacing between Boards

2.4 1.15, 1.16 Proper board placement in pallet (if used) Operator Training

2.5 Conveyer cover (if required) In place

3.0 Unloading

3.1 3.9 ESD Control Per ANSI S20.20

3.2 1.15, 1.16 Proper Handling Operator Training

3.3 Cooling/Ion Blowers

3.3.1 Filters presence Per control plan

3.3.2 1.6 Proper location on conveyor Per spec/set-up

3.3.3 Blower Operation indicator Per control plan

3.4 Magazines / Unloading racks

3.4.1 Correct Type for product (Pb/Pb free) Per control plan

3.4.2 Correct width and height for product Per control plan

3.4.3 Correct loading sequence (top down) Per control plan

3.4.4 Covered for transportation and storage Per control plan

3.5 Pallet Cleaning Per control plan

4.0 Component Compatibility

4.1 1.6 Component Spec

4.2 1.6 Components surface finish compatible with solder Component Spec

4.3 1.6 Solder Pot Elemental Analysis Product specification

4.4 Prevention of Pb/Pb-free solder bar mix Proper error-proofing

5.0 Warpage Control

5.1 Maximum diagonal warpage meets standard

6.0 Abnormal Condition Reaction

Dross Removal Frequency from Solder Pot (if required)

1.42.112.12

Automatic/operator training

1.42.112.12

1.42.112.12

Components compatible with solder / pre heat temperature

1.42.112.12

Per IPC-TM-650, Section 2.4.22, or per customer requirement

1.42.112.12

Page 274: Supplier Evaluation (QVR)Rev6 0112

6.1 2.8 Power failure reaction plan Control plan

6.2 2.8 Emergency-stop reaction plan Control plan

6.3 2.8 Part jam reaction plan Control plan

6.4 2.8 Drop part reaction plan Control plan

6.5 2.8 In Process Delay Reaction Plan Control plan

6.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

Based on IPC-7711, 7721

Page 275: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

Continuous

Continuous

PM Completion Report

Continuous

Flow Meter

Continuous

Per control plan

Continuous

Continuous

Continuous

Set-up Sheet

Per control plan

Per control plan

Continuous

Continuous

Continuous

Design Review

- Dip Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Per control plan/changeover

Cover PageCover Page Index PageIndex Page

Page 276: Supplier Evaluation (QVR)Rev6 0112

Check sheet

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Daily Check Sheet

Daily Check Sheet

Continuous

Continuous

Continuous

Continuous

Per Control Plan

Design Review

Design Review

100%

Per Preventative Maintenance

Pb-free; Quarterly Lab Results, Pb; annual lab results

Changeover/profile modification

Page 277: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 278: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Equipment

1.1 Flux Application See Process Table F

1.2 Pre-heat Process See Process Table G

1.3 Temperature controller Automatic

1.3.1 Tin-Lead Solder Correct Profile

1.3.2 Lead Free Solder Correct Profile

1.4 Heating element Proper PM

1.5 Atmosphere control

1.5.1 Ventilation Automatic

1.5.2 Nitrogen supply system (if used) Automatic

1.5.3 Oxygen monitoring system (if used) Automatic

1.5.4 Solder pot level control Automatic

1.6 Conveyers

1.6.1 Width control Per set-up

1.6.2 Speed control

1.6.3 Infeed cover In place

1.6.4 Finger Cleaner Per control plan

1.7 M.O.L.E. / Surveyor

1.7.1 Thermal couple board placement Based on board layout

1.7.2 Frequency of sampling Per control plan

1.8 Solder supply control

1.8.1 Solder pump RPM (if used) Per control plan

1.8.2 Wave Vibrational Control (if used) Per control plan

1.9 3.9 ESD Control Per ANSI S20.20

1.10 Lead/Lead free changeovers

1.11 1.6 Equipment lead-free compatible

PROCESS TABLE K - Selective Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Automatic per Control Plan

Proper equipment cleaning

Per equipment specification

Page 279: Supplier Evaluation (QVR)Rev6 0112

1.12 Dross Removal Frequency Per control plan

2.0 Loading

2.1 Correct Orientation

2.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training

2.3 1.15, 1.16 Correct Spacing

2.4 1.15, 1.16 Proper placement in pallet (if used) Operator Training

3.0 Unloading

3.1 3.9 ESD Control Per ANSI S20.20

3.2 1.15, 1.16 Proper Handling Operator Training

3.3 Cooling/Ion Blowers

3.3.1 Filters presence Per control plan

3.3.2 1.6 Proper location on conveyor Per spec/set-up

3.3.3 Blower Operation indicator Per control plan

3.4 Magazines / Unloading racks

3.4.1 Correct Type for product (Pb/Pb free) Per control plan

3.4.2 Correct width and height for product Per control plan

3.4.3 Correct loading sequence (top down) Per control plan

3.4.4 Covered for transportation and storage Per control plan

3.5 Pallet Cleaning Per control plan

4.0 Component Compatibility

4.1 1.6 Component Spec

4.2 1.6 Components compatible with solder Component Spec

4.3 1.6 Solder Pot Elemental Analysis Product specification

4.4 Prevention of Pb/Pb-free solder bar mix Proper error-proofing

5.0 Warpage Control

5.1 Maximum diagonal warpage meets standard

6.0 Abnormal Condition Reaction

6.1 2.8 Power failure reaction plan Control plan

1.42.112.12

Automatic/operator training

Automatic/operator training

1.42.112.12

1.42.112.12

Components compatible with solder / pre heat temperature

1.42.112.12

Per IPC-TM-650, Section 2.4.22, or per customer requirement

1.42.112.12

Page 280: Supplier Evaluation (QVR)Rev6 0112

6.2 2.8 Emergency-stop reaction plan Control plan

6.3 2.8 Part jam reaction plan Control plan

6.4 2.8 Drop part reaction plan Control plan

6.5 2.8 In Process Delay Reaction Plan Control plan

6.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

Based on IPC-7711, 7721

Page 281: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

Continuous

Continuous

PM Completion Report

Continuous

Continuous

Continuous

Continuous

Per control plan

Continuous

Continuous

Continuous

Per control plan

Per control plan

Continuous

Continuous

Continuous

Design Review

- Selective Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Per control plan/changeover

Cover PageCover Page Index PageIndex Page

Page 282: Supplier Evaluation (QVR)Rev6 0112

Check sheet

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Daily Check Sheet

Daily Check Sheet

Continuous

Continuous

Continuous

Continuous

Per Control Plan

Design Review

Design Review

100%

Continuous

Per Preventative Maintenance

Pb-free; Quarterly Lab Results, Pb; annual lab results

Changeover/profile modification

Page 283: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Continuous

Page 284: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Equipment

1.1 Flux Application (if used) See Process Table F

1.2 Pre-heat Process (if used) See Process Table G

1.3 Conveyer

1.3.1 Width control Per set-up

1.3.2 Speed/index control

1.3.3 Infeed cover In place

1.4 Soldering Iron

1.4.1 Temperature controller Correct Temperature

1.4.2 1.18 Heating element Proper PM

1.4.3 1.6 Iron tip temperature calibration Per specification

1.4.4 1.6 Correct Tip (shape/size/material) Per specification

1.4.5 Iron tip cleaner Per control plan

1.4.6 1.18 Iron tip maintenance Proper PM

1.5 Solder

1.5.1 1.6 Correct Solder (type/size/core) Per specification

1.5.2 Solder Lot Control Bar Code or Manual

1.6 Atmosphere control

1.6.1 Ventilation Automatic

PROCESS TABLE L - Automated Iron Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Automatic per Control Plan

Page 285: Supplier Evaluation (QVR)Rev6 0112

1.6.2 Nitrogen supply system (if used) Automatic

1.6.3 Oxygen monitoring system (if used) Automatic

1.7 3.9 ESD Control Per ANSI S20.20

1.8 Pb/Pb free changeovers

1.9 Solder ball control

2.0 Automated Solder Process Control

2.1 1.6 Tip contact position Per product spec

2.2 1.6 Tip contact dwell time Per product spec

2.3 1.6 Solder contact position Per product spec

2.4 1.6 Solder feed rate Per product spec

2.5 1.6 Angle of contact Per product spec

3.0 Loading

3.1 1.15, 1.16 Correct Orientation

3.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training

3.3 1.15, 1.16 Correct Spacing

3.4 1.15, 1.16 Proper placement in pallet (if used) Operator Training

4.0 Unloading

4.1 3.9 ESD Control Per ANSI S20.20

4.2 1.15, 1.16 Proper Handling Operator Training

4.3 Cooling/Ion Blowers

4..3.1 Filters presence Per control plan

4.3.2 1.6 Proper location on conveyor Per spec/set-up

4.3.3 Blower Operation indicator Per control plan

4.4 Magazines / Unloading racks Per product spec

Proper equipment cleaning

Solder preparation per customer agreement (e.g., V-groove cutter)

1.42.112.12

1.42.112.12

Automatic/operator training

Automatic/operator training

1.42.112.12

Page 286: Supplier Evaluation (QVR)Rev6 0112

4.4.1 Correct Type for product (Pb/Pb free) Per control plan

4.4.2 Correct width and height for product Per control plan

4.4.3 Correct loading sequence (top down) Per control plan

4.4.4 Covered for transportation and storage Per control plan

4.5 Pallet Cleaning Per control plan

5.0 Component Compatibility

5.1 1.6 Components compatible with iron temperature Component Spec

5.2 1.6 Components compatible with solder Component Spec

6.0 Warpage Control

6.1

7.0 Abnormal Condition Reaction

7.1 2.8 Power failure reaction plan Control plan

7.2 2.8 Emergency-stop reaction plan Control plan

7.3 2.8 Part jam reaction plan Control plan

7.4 2.8 Drop part reaction plan Control plan

7.5 2.8 In Process Delay Reaction Plan Control plan

7.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

1.42.112.12

1.42.112.12

Maximum diagonal warpage meets standard (warpage of the PCB cannot be affected by this process).

Per IPC-TM-650, Section 2.4.22

1.42.112.12

Based on IPC-7711, 7721

Page 287: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Per control plan

Continuous

Continuous

Continuous

PM Completion Report

Per control plan

Per control plan

Continuous

PM Completion Report

Per control plan

Per control plan

Continuous

- Automated Iron Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 288: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

100%

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Daily Check Sheet

Daily Check Sheet

Per Changeover

Per control plan/changeover

Per Preventative Maintenance

Page 289: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Per Control Plan

Design Review

Design Review

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Changeover/profile modification

Page 290: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Equipment

1.1 Flux Application (if used) See Process Table F

1.2 Pre-heat Process (if used) See Process Table G

1.3 Soldering Iron

1.3.1 Temperature controller Correct Temperature

1.3.2 Heating element Proper PM

1.3.3 1.6 Iron tip temperature calibration Per specification

1.3.4 1.6 Correct Tip (shape/size/material) Per specification

1.3.5 Iron tip cleaner Per control plan

1.3.6 Iron tip maintenance Proper PM

1.3.7 Iron tip cleaner Per control plan

1.4 Solder

1.4.1 1.6 Correct Solder (type/size/core) Per specification

1.4.2 Solder Lot Control Bar Code or Manual

1.5 Atmosphere control

1.5.1 Ventilation Automatic

1.5.2 Nitrogen Soldering Protection (if used)

1.6 3.9 ESD Control Per ANSI S20.20

1.7 Pb/Pb free changeovers

PROCESS TABLE M - Manual Iron Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Proper equipment cleaning

Page 291: Supplier Evaluation (QVR)Rev6 0112

1.8 Solder ball control

2.0 Manual Solder Process Control

2.1

3.0 Loading/Unloading

3.1 3.9 ESD Control Per ANSI S20.20

3.2 1.15, 1.16 Proper Handling Operator Training

3.3 Ionizers

3.3.1 Filters presence Per control plan

3.3.2 1.6 Proper location on conveyor Per spec/set-up

3.3.3 Blower Operation indicator Per control plan

3.3.4 Proper maintenance Proper PM

3.4 1.6 Magazines / Unloading racks Per product spec

3.4.1 Correct Type for product (Pb/Pb free) Per control plan

3.4.2 Correct width and height for product Per control plan

3.4.3 Correct loading sequence (top down) Per control plan

3.4.4 Covered for transportation and storage Per control plan

3.5 Pallet Cleaning Per control plan

4.0 Component Compatibility

4.1 1.6 Components compatible with iron temperature Component Spec

4.2 1.6 Components compatible with solder Component Spec

5.0 Warpage Control

5.1 Maximum diagonal warpage meets standard

6.0 Abnormal Condition Reaction

Solder preparation per customer agreement (e.g., V-groove cutter)

1.42.112.12

Soldering techniques, such as; dwell times, methods of iron application to joint.

Retraining provided when quality issues indicate

1.42.112.12

1.42.112.12

1.42.112.12

Per IPC-TM-650, Section 2.4.22

1.42.112.12

Page 292: Supplier Evaluation (QVR)Rev6 0112

6.1 2.8 Power failure reaction plan Control plan

6.2 2.8 Emergency-stop reaction plan Control plan

6.3 2.8 Part jam reaction plan Control plan

6.4 2.8 Drop part reaction plan Control plan

6.5 2.8 In Process Delay Reaction Plan Control plan

6.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

Based on IPC-7711, 7721

Page 293: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

PM Completion Report

Per control plan

Per control plan

Continuous

PM Completion Report

Continuous

Per control plan

Per control plan

Continuous

Continuous

- Manual Iron Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Per control plan/changeover

Cover PageCover Page Index PageIndex Page

Page 294: Supplier Evaluation (QVR)Rev6 0112

100%

Post solder inspection

Continuous

Continuous

Daily Check Sheet

Daily Check Sheet

PM Completion Report

Per Changeover

Continuous

Continuous

Continuous

Continuous

Per Control Plan

Design Review

Design Review

Per Preventative Maintenance

Changeover/profile modification

Page 295: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 296: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Laser - Soft Beam Solder Equipment

1.1 Automated Flux Application See Process Table F

1.2 Manual Flux Application

1.2.1 1.15, 1.16 Correct Flux Type Operator Training

1.2.2 1.15, 1.16 Correct Applicator Operator Training

1.2.3 1.15, 1.16 Correct Amount and Location Operator Training

1.2.4 Time

1.3 Conveyer

1.3.1 Conveyer width control Per set-up

1.3.2 Conveyer speed control

1.3.3 Conveyer infeed cover In place

1.4 Pre-heat Process (if used) See Process Table G

2.0 Laser Equipment Controls

2.1 Correct Laser Wave Length Per Control Plan

2.2 Correct Laser Power Per Control Plan

2.3 Correct Laser Alignment Per Control Plan

2.4 Correct Laser Exposure Time Per Control Plan

2.5 Correct Laser Focus (Spot Size) Per Control Plan

PROCESS TABLE N - Laser - Soft Beam Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Automatic per Control Plan

1.42.112.12

Page 297: Supplier Evaluation (QVR)Rev6 0112

3.0 Soft Beam Equipment Controls

3.1 Correct Xenon Lamp Per Control Plan

3.2 Correct Power Setting Per Control Plan

3.3 Correct Alignment Per Control Plan

3.4 Correct Exposure Time Per Control Plan

3.5 Correct Focus (Spot Size) Per Control Plan

3.6 3.9 ESD Control Per ANSI S20.20

3.7 Lead/Lead free changeovers

4.0 Loading/Unloading

4.1 3.9 ESD Control Per ANSI S20.20

4.2 1.15, 1.16 Proper Handling Operator Training

4.3 Cooling/Ionizer Blower

4.3.1 Filters presence Per control plan

4.3.2 1.6 Proper location on conveyor Per spec/set-up

4.3.3 Blower Operation indicator Per control plan

4.3.4 Proper maintenance Proper PM

4.4 1.6 Magazines / Unloading racks Per product spec

4.4.1 Correct Type for product (Pb/Pb free) Per control plan

4.4.2 Correct width and height for product Per control plan

4.4.3 Correct loading sequence (top down) Per control plan

4.4.4 Covered for transportation and storage Per control plan

4.5 Pallet Cleaning Per control plan

5.0 Component Compatibility

5.1 1.6 Components compatible with temperature profile Component Spec

5.2 1.6 Components compatible with solder Component Spec

1.42.112.12

Proper equipment cleaning

1.42.112.12

1.42.112.12

Page 298: Supplier Evaluation (QVR)Rev6 0112

6.0 Abnormal Condition Reaction

6.1 2.8 Power failure reaction plan Control plan

6.2 2.8 Emergency-stop reaction plan Control plan

6.3 2.8 Part jam reaction plan Control plan

6.4 2.8 Drop part reaction plan Control plan

6.5 2.8 In Process Delay Reaction Plan Control plan

6.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

1.42.112.12

Based on IPC-7711, 7721

Page 299: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Per Training Plan

Per Training Plan

Per Training Plan

Per control plan

Continuous

Continuous

Per Specification

Per Set-Up Sheet

Per Set-Up Sheet

Per Set-Up Sheet

Per Set-Up Sheet

- Laser - Soft Beam Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 300: Supplier Evaluation (QVR)Rev6 0112

Per Specification

Per Set-Up Sheet

Per Set-Up Sheet

Per Set-Up Sheet

Per Set-Up Sheet

Continuous

Continuous

Continuous

Daily Check Sheet

Daily Check Sheet

PM Completion Report

Per Changeover

Continuous

Continuous

Continuous

Continuous

Per Control Plan

Design Review

Design Review

Per control plan/changeover

Per Preventative Maintenance

Page 301: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 302: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Solder Paste Control (Pre-mixed only)

1.1 1.6 Correct solder paste Specification

1.2 1.6 Correct storage conditions Specification

1.3 1.6 Correct stabilization Specification

1.4 1.6 Ambient temperature exposure Specification

2.0 Solder Paste Application

2.1 1.6 Dispensed volume Specification

2.2 1.6 Correct dispense location Specification

2.3 Nozzle condition Control Plan

3.0 Part Placement

3.1 1.6 Stationary part accuracy

3.2 1.6 Placement verification

3.3 1.6 Movable part accuracy

3.4 1.6 Movable part verification

3.5 1.6 Gap between parts to be soldered

4.0 Equipment Control

4.1 1.6 Power Supply Frequency Per Specification

PROCESS TABLE O - InductionThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

1.42.112.12

1.42.112.12

Per Set-Up Specification

Per Set-Up Specification

Per Set-Up Specification

Per Set-Up Specification

Per Set-Up Specification

1.42.112.12

Page 303: Supplier Evaluation (QVR)Rev6 0112

4.2 1.6 Inductive Head Position (Hot Spot position control) Per Specification

4.3 1.6 Inductive Head to Part Gap Per Specification

4.4 1.6 Power Profile Per Specification

4.5 1.6 Power Duration per Soldering Cycle Per Specification

4.6 1.6 Inductive Head Cooling Air Flow Rate Per Specification

4.7 1.6 Magnetic Flux Monitoring Per Specification

5.0 Final Inspection

5.1 1.6 Quality Inspection Audit Per Specification

5.2 Non-conforming part disposition Reaction plan

6.0 Loading/Unloading

6.1 3.9 ESD Control Per ANSI S20.20

6.2 1.15, 1.16 Proper Handling Operator Training

6.3 Cooling/Ionizer Blower

6.3.1 Filters presence Per control plan

6.3.2 1.6 Proper location on conveyor Per spec/set-up

6.3.3 Blower Operation indicator Per control plan

6.3.4 1.18 Proper maintenance Proper PM

6.4 1.6 Magazines / Unloading racks Per product spec

6.4.1 Correct Type for product (Pb/Pb free) Per control plan

6.4.2 Correct width and height for product Per control plan

6.4.3 Correct loading sequence (top down) Per control plan

6.4.4 Covered for transportation and storage Per control plan

6.5 Pallet Cleaning Per control plan

7.0 Component Compatibility

7.1 1.6 Components compatible with temperature profile Component Spec

1.42.112.12

1.42.112.12

1.42.112.12

Page 304: Supplier Evaluation (QVR)Rev6 0112

7.2 1.6 Components compatible with solder Component Spec

8.0 Abnormal Condition Reaction

8.1 2.8 Power failure reaction plan Control plan

8.2 2.8 Emergency-stop reaction plan Control plan

8.3 2.8 Part jam reaction plan Control plan

8.4 2.8 Drop part reaction plan Control plan

8.5 2.8 In Process Delay Reaction Plan Control plan

8.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

1.42.112.12

Based on IPC-7711, 7721

Page 305: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Start-up and changeover

Continuous

Start-up and changeover

Continuous

Start-up and changeover

Continuous

Start-up and changeover

Continuous

Once per Day

Continuous

Once per Day

Once per Day

Start-up and changeover

- InductionThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Cover PageCover Page Index PageIndex Page

Page 306: Supplier Evaluation (QVR)Rev6 0112

Start-up and changeover

Start-up and changeover

Start-up and changeover

Start-up and changeover

Start-up and changeover

Start-up and changeover

Per Control Plan

Per Control Plan

Continuous

Continuous

Daily Check Sheet

Daily Check Sheet

PM Completion Report

Per Changeover

Continuous

Continuous

Continuous

Continuous

Per Control Plan

Design Review

Per Preventative Maintenance

Page 307: Supplier Evaluation (QVR)Rev6 0112

Design Review

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 308: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Conformal Coating

1.6 Type Used: Per Specification

1.6 Curing Method: Per Specification

2.0 Preparation

2.1 Pre-Mixed:

2.1.1 1.6 Correct Storage Conditions Per Specifications

2.1.2 1.6 Stabilized to operating temperature Per Specifications

2.1.3 Correct Material Bar Code or Manual

2.1.4 Expiration Date/Lot Control Bar Code or Manual

2.1.5 Expired Material Handling Per Control Plan

2.2 On-site Mixed:

2.2.1 1.6 Correct Storage Conditions for Components Per Specifications

2.2.2 1.6 Correct mixing temperature Per Specifications

2.2.3 Correct Material Bar Code or Manual

2.2.4 Ingredient Expiration Date/Lot Control Bar Code or Manual

2.2.5 Expired ingredients handling Per Control Plan

2.2.6 Mixing tools calibrated Per Control Plan

2.2.7 Cleanliness of mixing containers and work area No foreign materials

2.2.8 1.6 Mixing time Per Specifications

2.2.9 1.6 Viscosity confirmation Per Specifications

2.2.10 1.6 Prepared conformal coating expiration date Per Specifications

3.0 Coating Application

3.1 Spray - Automatic or Manual

PROCESS TABLE P - Conformal CoatingThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

1.42.112.12

1.42.112.12

Page 309: Supplier Evaluation (QVR)Rev6 0112

3.1.1 1.6 Correct Coverage Area Per Specification

3.1.2 1.6 No Coating / Overspray In Exclusion Zone Per Specification

3.1.3 1.6 Correct Thickness / Uniformity Per Specification

3.1.4 Solution Flow Rate (if 3.1.3 not applicable) Per Control Plan

3.1.5 Solution Pressure Rate Per Control Plan

3.1.6 Nozzle Movement Speed Per Control Plan

3.1.7 1.18 Nozzle Maintenance

3.1.8 1.6 Masking (Manual Spray Only) Per Specification

1.6 Board and Solution Temperature

3.2 Dip - Automatic or Manual

3.2.1 1.6 Correct Coverage Area Per Specification

3.2.2 1.6 Correct Thickness / Uniformity

3.2.3 No Foreign Material in Pot Proper Filtering

3.2.4 1.6 Uniform viscosity maintenance

3.2.5 Insert and Withdraw Rate / Soak Time Per Control Plan

3.2.6 1.6 Correct board orientation Per Specification

3.2.7 1.6 Board and Tank Temperature

3.2.8 1.6 Drip Time

3.3 Brush

3.3.1 1.6 Correct Brush Type Per Specification

3.3.2 1.6 Correct Coverage Area Per Specification

3.3.3 1.6 No Coating / Oversplash In Exclusion Zone Per Specification

3.3.4 1.6 Correct Thickness / Uniformity Per Specification

3.3.5 1.6 Masking (If Required) Per Specification

3.3.6 1.6 Uniform viscosity maintenance

3.3.7 1.6 No Foreign Material in Pot Per Specification

3.3.8 1.6 Board and Tank Temperature

3.3.9 Proper ESD Control Per ANSI S20.20

3.4 Selective Coverage Area

3.4.1 1.6 Correct Coverage Area Per Specification

3.4.2 1.6 No Coating / Drips In Exclusion Zone Per Specification

3.4.8 1.6 Board and Solution Temperature

3.4.9 1.15, 1.16

Per Preventive Maintenance Schedule

Per Product Specification

Per Specification and Control Plan

Per Product Specification

Per Product Specification

Per Product Specification

Per Product Specification

Per Product Specification

Per Product Specification

Proper Coverage for Manual Applications with controls as above

Proper Operator Training

Page 310: Supplier Evaluation (QVR)Rev6 0112

4.0 Curing

4.1 Ultra Violet (UV) Cure

4.1.1 1.6 Proper UV Source Per Specification

4.1.2 1.6 Proper Exposure Time Per Specification

4.1.3 1.6 Debris Control Per Specification

4.1.4 1.6 Correct Orientation Per Specification

4.1.5 Proper UV Source Maintenance

4.1.6 1.6 Humidity Control

4.2 Humidity Cure

4.2.1 1.6 Correct Temperature / Humidity Range Per Specification

4.2.2 1.6 Proper Exposure Time Per Specification

4.2.3 1.6 Debris Control Per Specification

4.2.4 1.6 Correct Orientation Per Specification

4.3 Heat Cure

4.3.1 1.6 Correct Temperature Level Per Specification

4.3.2 1.6 Proper Exposure Time Per Specification

4.3.3 1.6 Debris Control Per Specification

4.3.4 1.6 Correct Orientation Per Specification

4.3.5 1.6 Proper Humidity Level Per Specification

4.4 Ambient Cure

4.4.1 1.6 Correct Temperature / Humidity Range Per Specification

4.4.2 1.6 Proper Cure Time Per Specification

4.4.3 1.6 Debris Control Per Specification

4.4.4 1.6 Correct Orientation Per Specification

5.0 Inspection

5.1 1.15, 1.16 Proper Coverage Area Operator Training

5.2 No Bubbles, Voids, or Inconsistencies None Allowed

5.3 Thickness Check

5.4 1.15, 1.16 Curing Completion Operator Training

5.5 3.9 Proper ESD Control Per ANSI S20.20

6.0 General

6.1 Fixture cleaning frequency Per Control Plan

6.2 Appropriate operator protective equipement

1.42.112.12

Per Preventive Maintenance Schedule

Per Coating Specifications

1.42.112.12

Per Product Specification

1.42.112.12

Per work area requirement

Page 311: Supplier Evaluation (QVR)Rev6 0112

7.0 Abnormal Condition Reaction

7.1 2.8 Power failure reaction plan Control plan

7.2 2.8 Emergency-stop reaction plan Control plan

7.3 2.8 Part jam reaction plan Control plan

7.4 2.8 Drop part reaction plan Control plan

7.5 2.8 In Process Delay Reaction Plan Control plan

7.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

1.42.112.12

Based on IPC-7711, 7721

Page 312: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

Check sheet

Every Container

Every Container

Per Control Plan

Per Control Plan

Check sheet

Every Container

Every Container

Per Control Plan

Per Calibration Cycle

Check sheet

Check sheet

Check sheet

- Conformal CoatingThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Error-Proofing Check Sheet

Error-Proofing Check Sheet

Per Control Plan/Work Instructions

Cover PageCover Page Index PageIndex Page

Page 313: Supplier Evaluation (QVR)Rev6 0112

Set-up Sheet

Set-up Sheet

Set-up Sheet

Set-up Sheet

Set-up Sheet

Set-up Sheet

Continuous

Continuous

Set-up Sheet

Set-up Sheet

Set-up Sheet

Set-up Sheet

Continuous

Continuous

Continuous

Set-up Sheet

Set-up Sheet

Set-up Sheet

Set-up Sheet

Continuous

Set-up Sheet

Set-up Sheet

Continuous

Continuous

Set-up Sheet

Set-up Sheet

Continuous

Visual Control

Maintenance Check Sheet

PM Schedule per customer requirement

Page 314: Supplier Evaluation (QVR)Rev6 0112

Set-up Sheet

Set-up Sheet

Set-up Sheet

Continuous

Set-up Sheet

Set-up Sheet

Set-up Sheet

Continuous

Set-up Sheet

Set-up Sheet

Set-up Sheet

Continuous

Continuous

Set-up Sheet

Set-up Sheet

Set-up Sheet

Continuous

Continuous

Continuous

Per Sampling Plan

Continuous

Continuous

Per Schedule

100%

Maintenance Check Sheet

Plant Level:Equipment Level:

Page 315: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 316: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Router

1.1 1.6 Correct router pattern Specification

1.2 1.6 Correct bit Specification

1.3 1.6 Correct bit alignment Specification

1.4 1.6 Correct RPM Specification

1.5 Correct debris removal Proper vacuum level

1.6 No abnormal board flex

1.7 3.9 ESD control Per ANSI S20.20

1.8 1.15, 1.16 Proper seating of PCB Operator training

1.9 1.6 Proper support for separated panels Specification

1.10 1.15, 1.16 Proper handling during loading and unloading Operator training

1.11 1.18 Established bit preventive maintenance

1.12 Reaction plan to broken bit Per Control Plan

2.0 Die/Punch

2.1 Correct die/punch Set-up Sheet

2.2 1.6 Correct PCB to die/punch alignment Specification

2.3 1.6 Correct force Specification

2.4 Correct debris removal Per control plan

2.5 No abnormal board flex

PROCESS TABLE Q - PCB SeparationThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Per Customer requirement

Per Preventive Maintenance Schedule

1.42.112.12

Per Customer requirement

Page 317: Supplier Evaluation (QVR)Rev6 0112

2.6 3.9 ESD control Per ANSI S20.20

2.7 1.15, 1.16 Proper seating of PCB Operator training

2.8 1.6 Proper support for separated panels Specification

2.9 1.15, 1.16 Proper handling during loading and unloading Operator training

2.10 1.18 Established die/punch preventive maintenance

2.11 Reaction plan to broken die/punch Per Control Plan

3.0 Blade (V-cut)

3.1 Correct blade Set-up Sheet

3.2 1.6 Correct PCB to blade alignment Specification

3.3 1.6 Correct PCB to blade gap Specification

3.4 Correct debris removal Pre control plan

3.5 No abnormal board flex

3.6 3.9 ESD control Per ANSI S20.20

3.7 1.15, 1.16 Proper seating of PCB Operator training

3.8 1.6 Proper support for separated panels Specification

3.9 1.15, 1.16 Proper handling during loading and unloading Operator training

3.10 1.18 Established blade preventive maintenance

3.11 Reaction plan to damage blade Per Control Plan

4.0 Manual Separation

4.1 Correct debris removal Pre control plan

4.2 No abnormal board flex

4.3 3.9 ESD control Per ANSI S20.20

4.4

4.5 Proper handling during separation activity

4.6 Proper tools specified

Per Preventive Maintenance Schedule

1.42.112.12

Per Customer requirement

Per Preventive Maintenance Schedule

1.42.112.12

Per Customer requirement

Procedure in place to ensure separation method meets customer requirements

Per Customer requirement

Per Customer requirement

Per Customer requirement

Page 318: Supplier Evaluation (QVR)Rev6 0112

5.0 Abnormal Condition Reaction

5.1 2.8 Power failure reaction plan Control plan

5.2 2.8 Emergency-stop reaction plan Control plan

5.3 2.8 Part jam reaction plan Control plan

5.4 2.8 Drop part reaction plan Control plan

5.5 2.8 In Process Delay Reaction Plan Control plan

5.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

1.42.112.12

Based on IPC-7711, 7721

Page 319: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Continuous

Start-up or change over

Start-up or change over

Start-up or change over

Continuous

Continuous

Continuous

Continuous

Continuous

Start-up or change over

Start-up or change over

Start-up or change over

Continuous

- PCB SeparationThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Start of production or equipment change/modification

Start-up or equipment change-over

Maintenance Check Sheet

Start of production or equipment change/modification

Cover PageCover Page Index PageIndex Page

Page 320: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Start-up or change over

Start-up or change over

Start-up or change over

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Start-up or equipment change-over

Maintenance Check Sheet

Start of production or equipment change/modification

Start-up or equipment change-over

Maintenance Check Sheet

Start of production or equipment change/modification

Page 321: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Page 322: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 Automatic

1.2 Conveyer width control Per set-up

1.3 Conveyer index control

1.4 Conveyers covered Covers in place

1.5 Proper positioning for test Per set-up

1.6 Per set-up

1.7 Per set-up

1.8 Correct dwell (test/set) time Per set-up

1.9 Good/bad boundary sample confirmation

1.10 Proper test equipment calibration

1.11 Failed part data logging Per each failed part

1.12 Failed part traceability

1.13 Reaction plan to high level of false-fails Per reaction plan

1.14 Reaction plan to defective part limits Per reaction plan

1.15 1.18

1.16 3.9 ESD control Per ANSI S20.20

PROCESS TABLE R - In-circuit Testing (ICT)The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Automatic per Control Plan

Correct test set-up:SoftwareHardware

Correct pin set-up:Clearance between pinsHeightPressureType

Start-up/changeover and last off

Per calibration frequency

Per identification method

Preventative maintenance performed (confirm pogo pin inspection/replacement criteria)

Per Preventive Maintenance Schedule

Page 323: Supplier Evaluation (QVR)Rev6 0112

1.17 No abnormal board flex

2.0 Manual

2.1 1.15, 1.16 Correct loading/unloading Operator training

2.2 Proper positioning for test Per set-up

2.3 Per set-up

2.4 Per set-up

2.5 Correct dwell (test/set) time Per set-up

2.6 Good/bad boundary sample confirmation

2.7 Proper test equipment calibration

2.8 Failed part data logging Per each failed part

2.9 Failed part traceability

2.10 Reaction plan to high level of false-fails Per reaction plan

2.11 Reaction plan to defective part limits Per reaction plan

2.12 1.18

2.13 3.9 ESD control Per ANSI S20.20

2.14 No abnormal board flex

3.0 Abnormal Condition Reaction

3.1 2.8 Power failure reaction plan Control plan

3.2 2.8 Emergency-stop reaction plan Control plan

3.3 2.8 Part jam reaction plan Control plan

3.4 2.8 Drop part reaction plan Control plan

3.5 2.8 In-Process Delay Reaction Plan Control plan

Per Customer requirement

1.42.112.12

Correct test set-up:SoftwareHardware

Correct pin set-up:Clearance between pinsHeightPressureType

Start-up/changeover and last off

Per calibration frequency

Per identification method

Preventative maintenance performed (confirm pogo pin inspection/replacement criteria)

Per Preventive Maintenance Schedule

Per Customer requirement

1.42.112.12

Page 324: Supplier Evaluation (QVR)Rev6 0112

3.6 1.11 Repair/rework procedures

© 2010 Automortive Industry Action Group (AIAG)

Based on IPC-7711, 7721

Page 325: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Per control plan

Continuous

Continuous

Per control plan

Per control plan

Per control plan

Per control plan

Per control plan

Per control plan

Continuous

Per control plan

Per control plan

Continuous

- In-circuit Testing (ICT)The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Per equipment manufacturer recommendation

Maintenance Check Sheet

Cover PageCover Page Index PageIndex Page

Page 326: Supplier Evaluation (QVR)Rev6 0112

Per control plan

Per control plan

Per control plan

Per control plan

Per control plan

Per control plan

Per control plan

Continuous

Per control plan

Per control plan

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Start of production or equipment change/modification

Per equipment manufacturer recommendation

Maintenance Check Sheet

Start of production or equipment change/modification

Page 327: Supplier Evaluation (QVR)Rev6 0112

Continuous

Page 328: Supplier Evaluation (QVR)Rev6 0112

ITEM # Category/Process Steps Control

1.0 On-line Re-work

1.1 Confirmation of defective part

1.2 Written procedure

1.3 Traceability linked to part repair history Written procedure

1.4 Identify effective area of defect

1.5 Identify defective component

1.6

1.7 Written procedure

1.8 1.15, 1.16 Operator certification for diagnostic and repairs Operator training

1.9 Repair confirmed by certified supervisor/team leader

1.10 Written policy

1.11 3.9 ESD handling procedure in place Per ANSI S20.20

1.12 Solder ball control

PROCESS TABLE S - Solder Re-workThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.

Related SSA

Question

1.42.112.12

Defect class defined per customer agreement

Procedure to track defective part from the process through re-work

Quality confirmation systems

Quality confirmation systems

Identification method for reworkable components. (Proper IC orientation / part polarity)

Written policy or customer requirements

Removal of conformal coating, if required (not recommended)

Written policy or customer requirements

Repaired part returned to production line and inserted prior to defect identification/reject point

Solder preparation per customer agreement (e.g., V-groove cutter)

Page 329: Supplier Evaluation (QVR)Rev6 0112

2.0 Off-line Repair Procedure

2.1 Confirmation of defective part

2.2 Written procedure

2.3 Traceability linked to part repair history Written procedure

2.4 Off-line part handling and storage procedure Written procedure

2.5 Identify effective area of defect Inspection results

2.6 Identify defective component Inspection results

2.7 Identification method for reworkable components.

2.8 Written procedure

2.9 1.15, 1.16 Operator certification for diagnostic and repairs Operator training

2.10 Repair confirmed by certified supervisor/team leader

2.11 Written policy

2.12 3.9 ESD handling procedure in place Per ANSI S20.20

3.0 Repair Equipment and Material

3.1

3.2 All tools indentified for Pb versus Pb free

3.3 Solder iron

3.3.1 Correct Iron Temperature Per specification

3.3.2 Heating element Per specification

3.3.3 Iron tip temperature calibration Per specification

3.3.4 Correct Tip (shape/size/material) Per specification

3.3.5 Correct Solder (type/size/core) Per specification

3.3.6 Solder Lot Control Bar Code or Manual

1.42.112.12

Defect class defined per customer agreement

Defective parts tracked from the process through re-work

Written policy or customer requirements

Removal of conformal coating, if required (not recommended)

Written policy or customer requirements

Repaired part returned to production line and inserted prior to defect identification/reject point

1.42.112.12

Work stations identified for Pb versus Pb-free material

Visual identification and documentation

Visual identification and documentation

Page 330: Supplier Evaluation (QVR)Rev6 0112

3.3.7 Atmosphere control Automatic

3.3.8 Ventilation Automatic

3.3.9 3.9 ESD Control Per ANSI S20.20

3.3.10 Iron tip cleaner Per control plan

3.3.11 Iron tip maintenance

3.4

3.4.1 Removal - Localized pre-heat control

3.4.2 Removal - Pre-heat temperature set point

3.4.3 Removal - Pre-heat time control

3.4.4 Proper pad inspection post-removal Operator training

3.4.5 Insertion - Pre-heat control

3.4.6 Insertion - Reflow temperature control

3.4.7 Insertion - Reflow time control

3.4.8 Post insertion - Cooling profile

3.4.9 Heater head cleaning procedure

3.5 Component Control

3.5.1 Replacement component match bill of material

3.5.2

3.5.3 Component matches solder type used

3.5.4 Disposition of defective components

3.6 Conformal Coat removal and replacement

3.7.1 Solvent removal Procedure in place

3.7.2 Correct solvent for coating used

Per Preventive Maintenance Schedule

1.42.112.12

BGA/Flip Chip/Bumped Die/Controlled Collapse Chip Connection (C4) Repair Equipment

Automatic based on part requirements

Automatic based on part requirements

Automatic based on part requirements

Automatic based on part requirements

Automatic based on part requirements

Automatic based on part requirements

Automatic based on part requirements

Per equipment OEM specifications

1.42.112.12

BOM verification / crosscheck

Proper moisture sensitive device (MSD) environmental control/tracking

Per component requirements

BOM verification / crosscheck

Scrap / non-conforming part procedure

1.42.112.12

Procedure / checksheet

Page 331: Supplier Evaluation (QVR)Rev6 0112

3.7.3 1.15, 1.16 Mechanical dam installed around component

3.7.4 1.15, 1.16 Filler used for solvent to prevent run out

3.7.5 1.15, 1.16 Board cleaned before re-work

3.8 Micro-abrasive removal

3.8.1 1.15, 1.16 Only nonconductive abrasive allowed

3.8.2 1.15, 1.16 Mask used to protect surrounding components

3.8.3 1.15, 1.16 Board cleaned before re-work

3.9 Mechanical removal

3.9.1 1.15, 1.16 Proper tool

3.9.2 1.15, 1.16 No damage allowed to solder resist

3.10 1.15, 1.16 De-soldering removal

3.10.1 1.15, 1.16 Proper iron temperature to vaporize coating

3.10.2 1.15, 1.16 Proper ventilation for operator protection

3.11 Reapplication

3.11.1 1.15, 1.16

3.11.2 1.15, 1.16

3.11.3 1.15, 1.16

4.0 Encapsulated / Potted Component Rework Not recommended

5.0 Proper work station cleanliness Operator training

6.0 Abnormal Condition Reaction

6.1 2.8 Power failure reaction plan Control plan

6.2 2.8 Drop part reaction plan Control plan

6.3 2.8 In Process Delay Reaction Plan Control plan

6.4 1.11 Repair/rework procedures

6.5 1.11 Maximum number of repairs allowed per board

Procedure / Operator training

Procedure / Operator training

Procedure / Operator training

Procedure / Operator training

Procedure / Operator training

Procedure / Operator training

Procedure / Operator training

Procedure / Operator training

Procedure / Operator training

Procedure / Operator training

Procedure / Operator training

Silicone paste conformal coat only one part moisture cured solution allowed

Procedure / Operator training

Non-silicone paste adhesion promoter should be used as needed

Procedure / Operator training

All repairs require at least 3 millimeters overlap of demarcation edges of existing coatings

Procedure / Operator training

1.42.112.12

1.42.112.12

1.42.112.12

Based on IPC-7711, 7721

Per customer product specification

Page 332: Supplier Evaluation (QVR)Rev6 0112

© 2010 Automortive Industry Action Group (AIAG)

Page 333: Supplier Evaluation (QVR)Rev6 0112

Monitoring Auditor Notes

Automatic test

Control Plan

Control Plan

Control Plan

Control Plan

Control Plan

Control Plan

Control Plan

Control Plan

Continuous

100%

- Solder Re-workThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.  All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content.  The information is not to be sold in part or whole to anyone within your organization or to another company. 

Copyright infringement is a violation of federal law subject to criminal and civil penalties.  AIAG and the Automotive Industry Action Group are registered service marks of the Automotive

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.

Training matrix with annual management review.

Cover PageCover Page Index PageIndex Page

Page 334: Supplier Evaluation (QVR)Rev6 0112

Automatic test

Control Plan

Control Plan

Control Plan

Control Plan

Control Plan

Control Plan

Control Plan

Control Plan

Control Plan

Continuous

Continuous

Continuous

Quality audit

Per PM Schedule

Per control plan

Per control plan

Per control plan

Per control plan

Training matrix with annual management review.

Page 335: Supplier Evaluation (QVR)Rev6 0112

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

Continuous

PM completion reports

Continuous

Continuous

Continuous

Continuous

Supervisor confirmation

Supervisor confirmation

Maintenance Check Sheet

Page 336: Supplier Evaluation (QVR)Rev6 0112

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Supervisor confirmation

Continuous

Continuous

Continuous

Continuous

Effective tracking system

Page 337: Supplier Evaluation (QVR)Rev6 0112

REQUIREMENT CATEGORIES

SP Special Processes

1 0 Heat Treat Services Provided [YES / NO]

2 0 Plating Services Provided [YES / NO]

3 0 Coating Services Provided [YES / NO]

4 0 Welding Services Provided [YES / NO]

5 0 Soldering Services Provided [YES / NO]

"'YES" / "NO"

"'YES" / "NO"

IF YOU HAVE ANSWERED "NO" TO ANY OF THE QUESTIONS BELOW IN CELLS C3, C4, OR C5, PLEASE CLICK THE "NO" BUTTON FOR THAT LINE. THIS WILL ELIMINATE THE SPECIAL PROCESSES WORKSHEET

ATTACHED! THIS WILL REDUCE THE OVERALL SIZE OF THE WORKSHEET

Does this process require Heat Treat?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.

Does this process require Plating?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.

Does this process require Coating?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.

Does this process require Welding?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.

Does this process require Soldering?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.

Cover PageCover Page

Index PageIndex Page