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Facility Name:
Address:
Personnel Contacted:
Name: Title: Phone: Email:
Auditors/Assessors:
Name: Company: Phone: Email:
Assessment
Assessment
Assessment
Assessment
Assessment
Assessment
Assessment
Assessment
Section 1 - Management
Section Responsibility
2 - Floor and Material andResponsibility
Handling Quality Planning
Does the facility ensure that
Documented processes and evidence of compliance
the data entered in the
shall exist, e.g., shop travelers, work orders, etc. The
2.1 receiving system matches the
facility shall have a detailed process in place to
information on the customer's
resolve receiving discrepancies.
shipping documents?
Assessment
Assessment
Assessment
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:
Each part may have one or more requirements determined by the coating specification.
What are the product inspection 1.5
3.8 Parts must meet each requirement. List each requirement below and validate.
requirements? 2.13 2.14
(Listed below are some examples)
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
Requirement: Corrosion Resistance (if
3.8.2
applicable)
Test Method(s):
Test frequency or quantity:
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
3.8.4 Requirement: Adhesion
Test Method(s):
Test frequency or quantity:
Selection of samples:
Specification:
3.8.5 Requirement: Cure
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
Requirement: Torque Tension
3.8.6
(if applicable)
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
3.8.7 Requirement: Appearance (Decorative)
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
Requirement: Dimensional
3.8.8
(if applicable)
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
Requirement: Color and Gloss
3.8.9
(Decorative)
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
3.8.10 Requirement: Customer Specific
Test Method(s):
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:
1.4
1.6
Were appropriate process steps signed
3.9 2.2
off?
2.3
2.11
1.2
1.4
If additional steps were performed, were
3.12 1.6
they authorized?
1.10
1.16
Does the governing specification allow 1.5
3.13
reprocessing or rework? 1.10
Packaging Requirements
2.6
3.17 Are packaging requirements identified? 2.7
2.9
Are parts packaged to minimize mixed 2.6
3.18 parts (for example, parts packed over 2.7
height of container)? 2.9
Shipping Requirements
2.3
3.19 Were the parts properly identified?
2.9
2.3
3.20 Were the containers properly labeled?
2.9
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Related
Item # CSA Category/Process Steps Type of Control Monitoring Frequency Observation/Comments
Question #
Minimum
Actual Condition Minimum Requirement Actual Condition (Pass / Fail / N/A)
Requirement
1.4
Pressure for spray rinse.
A2.1 2.11 Automatic/Manual Once every 8 hours
Agitation for immersion tanks.
2.12
1.4
Continuous monitoring by controller.
A2.2 2.11 Temperature Automatic
Manually verify daily.
2.12
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Related
Item # CSA Category/Process Steps Type of Control Monitoring Frequency Observation/Comments
Question #
Minimum
Actual Condition Minimum Requirement Actual Condition (Pass / Fail / N/A)
Requirement
3.0 Rinse(s)
1.4
Pressure for spray rinse.
A3.1 2.11 Automatic/Manual Once every 8 hours
Agitation or flow for immersion tanks.
2.12
1.4
Continuous monitoring by controller.
A3.2 2.11 Temperature (if controlled) Automatic
Manually verify once per day.
2.12
A3.4 2.11 There is a dump schedule for rinses. Manual Per preventative maintenance schedule.
1.4
A4.1 2.11 Concentration Manual Once every 8 hours
2.13
1.4
A4.2 2.11 Concentration of Fe, per coating supplier. Manual Once per day
2.12
1.4
A4.3 2.11 Inhibitor (if used) Manual N/A
2.12
1.4
A4.4 2.11 Solution Level Manual Once every 8 hours
2.12
1.4
A6.2 2.11 Concentrations of Al, per coating supplier. Manual Once per day
2.12
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Related
Item # CSA Category/Process Steps Type of Control Monitoring Frequency Observation/Comments
Question #
Minimum Requirement Actual Condition Minimum Requirement Actual Condition (Pass / Fail / N/A)
C2.3 2.11 There is a dump schedule for conditioner. Manual Once per week
Chemical Analysis:
- Phosphate: Free Acid, Total Acid, Iron Content, pH,
1.4
Accelerator Amount as Applicable
C3.3 2.11 Automatic/Manual Once every 4 hours
- Non-phosphate: Concentration, pH
2.12
- Chromate: Concentration, pH
- Non-chrome: Concentration, pH
1.4
Fluoride Ion Concentration (if aluminum is being
C3.4 2.11 Automatic/Manual Once every 4 hours
coated)
2.12
1.4
1.6
C3.5 Coating Weight/Thickness Manual Once every 8 hours*
2.11
2.12
1.4
C3.6 2.11 Crystal/Grain Size (If applicable) Manual Per customer requirement
2.12
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Related
Item # CSA Category/Process Steps Type of Control Monitoring Frequency Observation/Comments
Question #
Minimum Requirement Actual Condition Minimum Requirement Actual Condition (Pass / Fail / N/A)
1.4
C4.2 2.11 Pressure/Agitation Automatic Once every 8 hours
2.12
C4.3 2.11 There is a dump schedule for rinses. Manual Once per week
C5.4 2.11 There is a dump schedule for seal. Manual Once per week
1.4 There is a procedure to ensure dryness of parts prior Every change of lot number and each
C6.2 Visual
2.11 to subsequent coating. container.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Related
Item # CSA Category/Process Steps Type of Control Monitoring Frequency Observation/Comments
Question #
Minimum Requirement Actual Condition Minimum Requirement Actual Condition (Pass / Fail / N/A)
1.4
Bath parameters (pH, conductivity, solid content, temperature,
F2.1 2.11 Automatic/Manual Once every 8 hours
voltage) are checked and adjusted.
2.12
1.4
Oil contamination (Panel inspection for pin holes). Once per month and if any visual defects
F2.2 2.11 Manual
Oil bags must be available. are observed.
2.12
1.4 For manual process, prior to start of
1.6 production and every part change. For
F2.3 Cycle time/Line speed setup is checked. Automatic/Manual
2.11 automated process, at the start of
2.12 production and every process change.
1.4
1.17 Paint racks and/or barrels are visually inspected for cleanliness,
F2.9 Manual Each time parts are racked/loaded
2.11 excessive paint build-up, bent hooks, etc.
2.12
1.4
1.17 There is a paint rack/barrel maintenance program. Program
F2.10 Manual Per preventative maintenance schedule.
2.11 must define rack/barrel cleaning intervals.
2.12
1.4
F2.11 2.11 Saddle contact cleanliness (if applicable). Manual Once every 8 hours
2.12
1.4
1.17
F2.12 There is a tank cleaning and maintenance schedule. Manual Once every year
2.11
2.12
1.4
F2.13 2.11 Confirmation of ash content (pigment to binder ratio). Manual Once per month
2.12
1.4
F2.14 2.11 Analysis of accumulation of metallic impurities. Manual Once every 6 months
2.12
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Related
Item # CSA Category/Process Steps Type of Control Monitoring Frequency Observation/Comments
Question #
Minimum Requirement Actual Condition Minimum Requirement Actual Condition (Pass / Fail / N/A)
1.4
F3.1 2.11 The conductivity of the anolyte solution has been measured. Manual Once every 8 hours
2.12
1.4
F3.2 2.11 The pH of the anolyte solution has been measured. Manual Once every 8 hours
2.12
1.4
Oil contamination (Panel inspection for pin holes). Oil
F3.3 2.11 Manual Once every month
bags must be available.
2.12
1.4
F3.4 2.11 The anolyte solution is being circulated to each cell. Automatic/Manual Once every 8 hours
2.12
1.4
F3.5 2.11 Dump and clean schedule for anolyte is being maintained. Manual Per preventative maintenance schedule.
2.12
1.4
F3.6 2.11 Amperage draw has been checked on anodes. Automatic/Manual Per preventative maintenance schedule.
2.12
4.0 Rectifier
1.4
1.6 The proper voltage is being used for the load size. When each bar or rack enters the coating
F4.1 Manual
2.11 (Electronically Controlled with digital read-out) tank.
2.12
1.4
Once every 6 months or after any change
F4.2 2.11 The ramp up time to full voltage has been verified. Automatic/Manual
or maintenance of rectifier.
2.12
There is a visual indicator to alert personnel when system is
F4.3 2.10 Automatic Ongoing
energized.
1.4
1.17 The ripple of the rectifier has been checked by an approved Once per year or after any change or
F4.4 Automatic/Manual
2.11 electrician. maintenance of rectifier.
2.12
1.4
Immersion rinse tanks are operating at the proper levels and
F5.1 2.11 Automatic/Manual Once every 8 hours
tanks are being agitated correctly.
2.12
1.4
F5.2 2.11 There is sufficient permeate supplied to the rinse. Automatic/Manual Once every 8 hours
2.12
1.4
The pH and conductivity of the DI rinse water are measured. (If
F5.3 2.11 Manual Once every 8 hours
part of production process).
2.12
1.4
F5.4 2.11 Ultra filters are in use (not by-passed) and pressures monitored. Automatic/Manual Once every 8 hours
2.12
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Item # Related
CSA Category/Process Steps Type of Control Monitoring Frequency Observation/Comments
Question #
Minimum Requirement Actual Condition Minimum Requirement Actual Condition (Pass / Fail / N/A)
1.0
1.4
For each coating in use, proper cure or drying time parameters
1.6 Once every 3 months and after oven
I1.3 are verified based upon oven temperature profile and product Manual
2.11 modification or repair.
technical data sheet.
2.12
1.4
For manual process, prior to start of
1.6
Conveyor speed set point is verified. If conveyor is not used, production and every part change. For
I1.4 1.17 Automatic/Manual
time in oven is verified. automated process, at the start of
2.11
production and every process change.
2.12
Per oven manufacturer, filter supplier
I1.5 Air filter (if used) change is scheduled. Manual
recommendation.
Cure testing is performed per part specification on a production At oven start-up, every process change
I1.6 2.13 Manual
part. and once every 8 hours.
Coating adhesion test is performed per part specification on a At oven start-up, every process change
I1.7 2.13 Manual
production part. and once every 8 hours.
Appearance requirements checks (color, gloss etc.) are At oven start-up, every process change
I1.8 2.13 Manual
performed per part specification. and once every 8 hours.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
PROCESS EQUIPMENT
Wet Analysis:
Before use, chemicals must be
K1.6 2.14 X X X X X X Daily N/A
checked for shelf life and/or
expiration date
K1.7 2.14 Filters X X X X X X X Per process table N/A
Laboratory Balance (Weight
K1.8 2.14 X X X X Once per month N/A
Scale)
K1.9 2.14 Conductivity Meter X X X X X X Once per month N/A
K1.10 2.14 Viscosity cup X X Twice per month N/A
Once every 6
K1.11 Thermocouple X X X X X X X N/A
months
K1.12 2.14 Lab Oven Controller X X X X X X N/A Once per year
MINIMUM REQUIRED TESTING CAPABILITY
K2.1 2.14 Salt Spray Cabinet X X X X X X X X Daily per ASTM B117 N/A
K2.2 2.14 Water Immersion bath X X X X X Daily N/A
K2.3 2.14 Cure Testing X X X X X X Per Part N/A
K2.4 2.14 Adhesion Testing X X X X X X Per Part N/A
K2.5 2.14 Thickness Testing X X X X X X Per Part Once per year
K2.6 2.14 Solids Testing X X X X X Daily N/A
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 specifications or other
requirements.
Related
Item # CSA Category/Process Steps Monitoring Frequency Observation/Comments
Question #
1.0
L1.9 Dimensional check (e.g., Go-no go, Plug and Ring gage) Per customer specification