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CQI-11v2

Special Process: Plating System Assessment

© 2012 Automotive Industry Action Group, except that copyright is not claimed as to any
part of an original work prepared by a U.S. or state government officer or employee as part
of the person’s official duties.
Except as noted above, all rights are reserved by AIAG and no part of these materials may
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Industry Action Group. Automotive Industry Action Group makes no claim to any trademark
of a third party. Trademarks of third parties included in these materials are the property of
their respective owners

© 2012 Automotive Industry Action Group

© 2012 Automotive Industry Action Group


ISBN#: 9871605342443-90000

CQI-11v2
Dated: 2/2012 1
CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating System Assessment, 2nd Edition

Facility Name: DeKalb Metal Finishing


Address: 625 West 15th Street / PO Box 70 Auburn, IN 46706

Phone Number: 260-925-1820 Type(s) of Plating Processing at this Facility:


Fax Number: 260-925-5258 Process Table A:
Zinc
Number of Plating Employees at this Facility: 43 Zinc Alloy Plating

Captive Plater (Y/N): NO Process Table B:


Commercial Plater (Y/N): YES

Date of Assessment: 1/1/2014 Process Table C:

Date of Previous Assessment: 1/1/2013

Date of Re-assessment (if necessary):


Process Table E:

Process Table F:

Process Table G:

Process Table H:

Process Table I:

Process Table J :
Process Control and Testing Equipment

Current Quality Certification(s): ISO/TS 16949:2009

Personnel Contacted:
Name: Title: Phone: Email:
Matt Morris Quality Manager 260-925-1820 x114 mmorris@dekalbmetal.com

Auditors/Assessors:
Name: Company: Phone: Email:
Matt Morris Quality Manager 260-925-1820 x114 mmorris@dekalbmetal.com

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Number of "Not Satisfactory" Findings: 0

Number of "Needs Immediate Action" Findings: 0

Number of "Fail" Findings in the Job Audit(s): 0

Number of Process Table items identified as failed in Comments/Observation column: 0

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Section 1 - Management Responsibility and Quality Planning


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 DeKalb Metal Finishing's Lab Manager
Is there a dedicated and job description shall exist identifying the qualifications has more than 20 years of experience in
1.1 qualified plating person on- for the position including chemical and plating the plating/surface finishing industry. X
site? knowledge. The qualifications shall include a The Job Description for the position of
minimum of 5 years experience in plating and surface Lab Manager reflects this requirement.
finishing or a combination of formal
chemistry/chemical engineering education and plating
experience totaling a minimum of 5 years.

The plater shall incorporate a documented advance


quality planning procedure. A feasibility study shall be DeKalb Metal Finishing uses the AIAG
performed and internally approved for each part. manual as a reference for the creation
Similar parts can be grouped into part families for this and implimentation of APQP's. In
Does the plater perform effort as defined by the plater. After the part approval addition, we utilize Procedure 03 to
1.2 X
advanced quality planning? process is approved by the customer, no process further define our APQP policy.
changes are allowed unless approved by the Feasibility studies are done for each part
customer. The plater shall contact the customer when and are maintained both in hard copy
clarification of process changes is required. This and electronic format.
clarification of process changes shall be documented.

The plater 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.
DeKalb Metal Finishing uses the AIAG
The FMEA shall be written for each part or part family
manual as a reference for the creation
Are plater FMEA's up to date or they may be process-specific and written for each
and implimentation of FMEA's. In
1.3 and reflecting current process. In any case, they shall address all process X
addition, we utilize Procedure 03 to
processing? steps from part receipt to part shipment and all key
further define our FMEA policy. FMEAs
plating process parameters as defined by the plater. A
are process specific.
cross-functional team shall be used in the
development of the FMEA. All characteristics, as
defined by the plater and its customers, shall be
identified, defined, and addressed in the FMEA.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Section 1 - Management Responsibility and Quality Planning


The plater shall incorporate the use of a documented
Control Plan procedure and ensure the Control Plans
are updated to reflect current controls. The Control
Plans shall be written for each part or part family or
they may be process-specific and written for each
DeKalb Metal Finishing uses the AIAG
process. In any case, they shall address all process
manual as a reference for the creation
steps from part receipt to part shipment and identify all
and implimentation of Control Plans. In
equipment used and all key plating process
addition, we utilize Procedure 14, to
parameters as defined by the plater. A cross-
Are finish process Control further define our Control Plan policy .
functional team, including a production operator, shall
1.4 Plans up to date and reflecting Control Plans are created electronically X
be used in the development of Control Plans, which
current processing? and are directly linked to our lab controls
shall be consistent with all associated documentation
in order to ensure that changes to the
such as work instructions, shop travelers, and FMEAs.
control plan are immediatly
All special characteristics, as defined by the plater and
communicated to all affected parties.
its customers, shall be identified, defined, and
Control Plans are process specific.
addressed in the Control Plans. Sample sizes and
Frequencies for evaluation of process and product
characteristics shall also be addressed consistent with
the minimum requirements listed in the Process
Tables.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Section 1 - Management Responsibility and Quality Planning


To ensure all customer requirements are both
understood and satisfied, the plater 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 Chrysler. The plater shall
Are all plating related and have a process to ensure the timely review, Yes, these documents are sent to us by
referenced specifications distribution, and implementation of all customer and our customers. Additionally, we
current and available? For industry engineering standards and specifications and subscribe to a service that notifies us
1.5 X
example: SAE, AIAG, ASTM, changes based on customer-required schedule. This when specifications are updated. All
General Motors, Ford, and process shall be executed as soon as possible and documents are controlled electronically in
Chrysler. shall not exceed two weeks. The plater shall our document management software.
document this process of review and implementation,
and it shall address how customer and industry
documents are obtained, how they are maintained
within the plating organization, how the current status
is established, and how the relevant information is
cascaded to the shop floor within the two-week period.
The plater shall identify who is responsible for
performing these tasks.

The plater shall have written process specifications for


all active processes and identify all steps of the Job Setup Instructions are in place for
process including relevant operating parameters. each part we produce. These
Examples of operating parameters include process instructions include recommended cycle
temperatures, cycle times, load rates, rectifier times, recommended rectifier settings,
Is there a written process
settings, etc. Such parameters shall not only be pieces per rack, racks per frame,
1.6 specification for all active X
defined, they shall have operating tolerances as required engineering specification, color,
processes?
defined by the plater in order to maintain process thickness requirements, racking
control. All active processes should have a written requirements, packaging requirements,
process specification. These process specifications and other special requirements, as
may take the form of work instructions, job card, defined by each customer.
computer-based recipes, or other similar documents.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Section 1 - Management Responsibility and Quality Planning


To demonstrate each process is capable of yielding
acceptable product the plater 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 plater
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 DeKalb Metal Finishing utilizes a
Has a valid product capability
and in accordance with customer requirements. combination of Procedure 10 and
1.7 study been performed initially X
Capability study techniques shall be appropriate for Procedure 28 to define and meet the
and after process change?
the plating product characteristics, e.g. plate specified requirements.
thickness, corrosion resistance, etc.. Any specific
customer requirements shall be met. In the absence
of customer requirements, the plater 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.

The analysis of products and processes over time can


yield vital information for defect prevention efforts. DeKalb Metal Finishing uses an
Does the plater collect and The plater shall have a system to collect, analyze, and electronic system for gathering, storing,
analyze data over time, and react to product or process data over time. Methods and analyzing most types of data. This
1.8 X
react to this data? of analysis shall include ongoing trend or historical data is analyzed on an ongoing basis to
data analysis of special product or process make decision on lab, production and
parameters. The plater shall determine which quality management.
parameters to include in such analysis.

DeKalb Metal Finishing maintails all


Are records retained and All process control and testing records must be process control records in an SQL
1.9 available? retained for a minimum of one calendar year after the database for a minimum of one calendar X
year in which they were created. year after the year in which they were
created.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

ManagementSection 1 the
shall review - Management
oven monitoring Responsibility and Quality Planning
Does management review and systems/logs at intervals not to exceed 24 hours or
verify bake oven logs for parts prior to parts being released for shipment. The plater
1.10 requiring hydrogen shall have reaction plans for non-conformances to N/A X
embrittlement relief every 24 process requirements. This is to contain, at minimum,
hours? requirements for quarantining material and notifying
customer.

Are internal assessments


The plater shall conduct internal assessments on an
being completed on an annual Requirement is met through completion
1.11 annual basis, at a minimum, using the AIAG PSA. X
basis, at a minimum, of this survey.
Concerns shall be addressed in a timely manner.
incorporating AIAG PSA?

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 DeKalb Metal Finishing utilizes
Is there a system in place to well as those characteristics for which reprocessing is Procedure 40 to manage the
1.12 authorize reprocessing and is not permissible. All reprocessing activity shall require reprocessing. Referenced documents X
it documented? a new processing control sheet issued by qualified include Procedure 29 and Job Setup
technical personnel denoting the necessary plating Instructions.
modifications. Records shall clearly indicate when and
how any material has been reprocessed. The Quality
Manager or a designee shall authorize the release of
reprocessed product.

The quality management system shall include a


Does the Quality Department DeKalb Metal Finishing utilizes an
process for documenting, reviewing, and addressing
review, address, and electronic system for recording and
1.13 customer concerns and any other concerns internal to X
document customer and managing customer complaints and
the organization. A disciplined problem solving
internal concerns? rejections.
approach shall be used.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Section 1 - Management Responsibility and Quality Planning


The plater shall define a process for continual DeKalb Metal Finishing has a three tier
improvement for each plating process identified in the (Red, Yellow, Green) process
Is there a continual
scope of the PSA. The process shall be designed to management system for controlling the
improvement plan applicable
1.14 bring about continual improvement in quality and plating process and measuring process X
to each process defined in the
productivity. Identified actions shall be prioritized and improvement. This systems is monitored
scope of the assessment?
shall include timing (estimated completion dates). The as part of management review for
plater shall show evidence of program effectiveness. effectiveness verification.

Does the Quality Manager or


The Quality Manager or designee is responsible for The plant manager, in conjunction with
designee authorize the
1.15 authorizing and documenting appropriate personnel to the quality manager will determine the X
disposition of material from
disposition quarantine material. disposition of quarantined material.
quarantine status?

Procedures, work instructions and other


documentation are made available to all
personnel through our electronic
There shall be procedures and work instructions
Document Management software.
available to plating personnel covering the plating
Specific documents include Procedure
process. These procedures or work instructions shall
Are there procedures or work 08 (Contingency Plans), Procedure 19
include methods of addressing potential emergencies
instructions available to plating (Inspection and Testing), DMFWI112
1.16 (such as power failure), equipment start-up, X
personnel that define the (Plant Startup/Shutdown), DMFWI071
equipment shut-down, product segregation (See 2.8),
plating process? (Line 1 Startup), DMFWI072 (Line 1
product inspection, and general operating procedures.
Shutdown), DMFWI073 (Line 2 Startup),
These procedures or work instructions shall be
DMFWI074 (Line 2 Shutdown),
accessible to shop floor personnel.
DMFWI075 (Line 3 Startup), DMFWI076
(Line 3 Shutdown), DMFWI077 (Line 4
Startup), DMFWI078 (Line 4 Shutdown)

The plater shall provide employee training for all


plating operations. All employees, including backup
and temporary employees, shall be trained. DeKalb Metal Finishing educates
Documented evidence shall be maintained showing employees on plating operations utilizing
Is management providing
1.17 the employees trained and the evidence shall include Program 1000 and Program 2000. X
employee training for plating?
an assessment of the effectiveness of the training. Documented evidence is maintained
Management shall define the qualification electronically in Iour training software.
requirements for each function, and ongoing or follow-
up training shall also be addressed.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Section 1 - Management Responsibility and Quality Planning


The plater shall maintain a responsibility matrix
Is there a responsibility matrix identifying all key management and supervisory DeKalb Metal Finishing utilizes a
to ensure that all key functions and the qualified personnel who may Responsibility Matrix (DMF301) to ensure
1.18 management and supervisory perform such functions. It shall identify both primary that all key management and supervisory X
functions are performed by and secondary (backup) personnel for the key functions are performed by qualified
qualified personnel? functions (as defined by the plater). This matrix shall personnel.
be readily available to management at all times.

The plater shall have a documented preventive


maintenance program for key process equipment (as
identified by the plater). The program shall be a
closed-loop process that tracks maintenance efforts
Is there a preventive from request to completion to assessment of
maintenance program? Is effectiveness. Equipment operators shall have the DeKalb Metal Finishing utilizes a
maintenance data being opportunity to report problems, and problems shall spreedsheet based maintenance log to
1.19 X
utilized to form a predictive also be handled in a closed-loop manner. Company manage its preventive / predictive
maintenance program? data, e.g., downtime, quality rejects, first time-through maintenance program.
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


The plater shall develop and maintain a critical spare
critical spare part list and are The critical spare parts list is included
1.20 parts list and shall ensure the availability of such parts X
the parts available to minimize this in the maintenance log.
to minimize production disruptions.
production disruptions?

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Section 1 - Management
Section 2 - Floor and Responsibility andResponsibility
Material Handling Quality Planning

Does the facility ensure that


Documented processes and evidence of compliance DeKalb Metal Finishings receiving
the data entered in the
shall exist, e.g., shop travelers, work orders, etc. The documents (DMF114, DMF135, DMF250,
2.1 receiving system matches the X
facility shall have a detailed process in place to or DMF324) are checked against
information on the customer's
resolve receiving discrepancies. customers incoming paperwork.
shipping documents?

Procedures for part and container identification help to


avoid incorrect processing or mixing of lots. Customer product is typically identified by
Appropriate location and staging within the facility also the customer on the packaging.
help to ensure that orders are not shipped until all Additionally, DeKalb Metal Finishing
Is product clearly identified
required operations are performed. Customer product labels the product during the receiving
2.2 and staged throughout the X
shall be clearly identified and staged throughout the process. Once the plating process is
plating process?
plating process. Non-plated, in-process, and finished completed, plated parts are moved to the
product shall be properly segregated and identified. warehouse where they are placed with
All material shall be staged in a dedicated and clearly "finished goods".
defined area.

Out-going lot(s) shall be traceable to the incoming


DeKalb Metal Finishing utilizes DMF114,
Is lot traceability and integrity lot(s). The discipline of precisely identifying lots and
DMF135, DMF250, or DMF324 to
2.3 maintained throughout all linking all pertinent information to them enhances the X
maintain lot integrity throughout all
processes? ability to do root cause analysis and continual
processes.
improvement.

The control of suspect or non-conforming product is


necessary to prevent inadvertent shipment or
contamination of other lots. Procedures shall be
Are procedures adequate to adequate to prevent movement of non-conforming DeKalb Metal Finishing utilizes
prevent movement of non- product into the production system. Procedures shall Procedure 29 to manage the integrity of
2.4 X
conforming product into the exist addressing proper disposition, product the non-conforming / hold area to unsure
production system? identification and tracking of material flow in and out segregation of such material.
of hold area. Non-conforming hold area shall be
clearly designated to maintain segregation of such
material.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Is there a system to identify Section 1 - Management Responsibility and Quality Planning


and inspect trap points in the
DeKalb Metal Finishing has identified
entire plating process to There shall be a list of trap points and work
2.5 trap points and posted these findings on X
reduce risk of mixed parts instructions detailing inspection frequencies.
signage located throughout the plant.
(inappropriate, unfinished, or
improperly plated parts)?

Containers handling customer product shall be free of


inappropriate material. After emptying and before re-
using containers, containers shall be inspected to
Are containers free of ensure that all parts and inappropriate material have DeKalb Metal Finishing uses customer
2.6 X
inappropriate material? been removed. The source of inappropriate material supplied containers.
shall be identified and addressed. This is to ensure
that no nonconforming plating parts or inappropriate
material contaminate the finished lot.
DeKalb Metal Finishing utilizes Job Setup
Loading parameters shall be specified, documented
Is part loading specified, Instructions to specify loading
2.7 and controlled. Examples include parts per rack and X
documented and controlled? parameters. These documents are
load size.
controlled electronially.

Unplanned or emergency downtime greatly raises the


risk of improper processing. Operators shall be
trained in material handling, containment action, and
Are operators trained in product segregation in the event of an equipment
DeKalb Metal Finisng trains operators on
material handling, containment emergency including power failure. Training shall be
material handling, containment, and
action and product documented. Work instructions specifically
2.8 product segrigation. This training is X
segregation in the event of an addressing potential types of equipment emergencies
verified through the use of our procedure
equipment emergency and failures shall be accessible to and understood by
quiz (DMF268).
including power failure? 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.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Is the handling, storage and The plater's Section 1 - Management


loading/unloading Responsibility
systems, in process and
DeKalb Metal Quality
Finishing Planning
utilizes
2.9 packaging adequate to handling and shipping process shall be assessed for Procedure 18 to ensure preservation of X
preserve product quality? risk of part damage or other quality concerns. product.

Plant cleanliness, housekeeping, environmental, and


working conditions shall be conducive to controlling DeKalb Metal Finishing utilizes
Are plant cleanliness,
and improving quality. The plater should evaluate Procedure 09, DMF194, and DMF253 to
housekeeping and
such conditions and their effect on quality. A manage facility cleanliness. Procedure
2.10 environmental and working X
housekeeping policy shall be clearly defined and 09 and DMF194 manage general plant
conditions conducive to
executed. The facility shall be reviewed for the cleanliness while DMF253 relates to
control and improved quality?
following items: loose parts on floor, spillage around building maintenance.
tanks, overall plant lighting, fumes etc.

Process control parameters shall be monitored per Process parameters are created,
Are process control frequencies specified in Process Tables. Computer monitored, and logged electronically and
parameters monitored per monitoring equipment with alarms and alarm logs are directly linked to the control plans.
2.11 X
frequencies specified in satisfy the verification requirement. A designated This ensures that changes made to the
Process Tables? floor person shall verify the process parameters, e.g., control plan are communicated to all
by initialing a strip chart or data log. affected parties immediately.

Cotrol points are identified and reviewed


Are there documented reaction plans to both out of electronically. When a control point
Are out of control/specification
control and out of tolerance process parameters? Is falls outside the specified range, affected
2.12 parameters reviewed and X
there documented evidence that reaction plans are parties are electronically notified and
reacted to?
followed? action is taken to ensure the control point
is restored to appropriate levels.
The resulting data from in process
Are In-Process / Final Test In-Process / Final Test Frequencies shall be inspection is stored electronically in an
2.13 Frequencies performed as performed as specified in Process Tables. Refer to SQL database. The resulting data from X
specified in Process Tables? Process Tables. final inspection is stored electronically in
our Final Audit Log spreadsheet.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Special Process: Plating Process Assessment (General Facility Overview)

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action

Section
Test equipment shall be 1 - Management
verified/calibrated per Responsibility and Quality Planning
applicable customer specific standard or per an
applicable consensus standard, e.g., ASTM, SAE, DeKalb Metal Finishing utilizes gage
Is product test equipment
2.14 ISO, NIST, etc. Verification/calibration results shall be calibration software to log and monitor X
verified?
internally reviewed, approved and documented. calibrations as well as MSA studies.

Refer to Process Tables for frequency of checks.

Identify operating parameters including:


- number of rinse tanks between process stages,
- tank type (single rinse, counter flowing, stationary
Are the water rinses controlled
rinse, spray rinse)
and detailed in the process Water Rinses are listed on the Control
2.15 - flow rate, X
Control Plan to reflect full Plans
- water requirements (city or deionized water, reverse
process parameters?
osmosis),
- filtration (if applicable)
- control methods.

© 2012 AIAG (Automotive Industry Action Group)


CQI-11
Special Process: Plating System Assessment
Version 2 Issued 2/2012

Section 3 - Zinc/ Zinc Alloy Plating Equipment

Assessment

Question Not Needs Immediate


Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action
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
Are process and testing notification system. Test equipment shall be
DeKalb Metal Finishing utilizes gage
equipment calibrations and/or verified/calibrated per applicable customer specific
3.1 calibration software to log and monitor X
verification certified, posted, standard or consensus standard, e.g., ASTM, SAE,
calibrations and MSA studies.
and current? ISO, NIST, etc. Verification/calibration results shall
be internally reviewed, approved and documented.
Refer to Process Table J, for equipment certification
time table.
Tooling is maintained on an on-going
basis as part of our preventive
Are barrels, racks, and Plater shall have preventative maintenance system
3.2 maintenance program. When racks are X
baskets maintained? that is documented and implemented.
found to be in disrepair, they are
repaired or replaced.
Plater shall have preventative maintenance system Rectifiers are included in our preventive
3.3 Are rectifiers maintained? X
that is documented and implemented. maintenance program.
Contact and bussing inspection are
Are Contacts and Bussing Plater shall have preventative maintenance system
3.4 included in our preventive maintenance X
maintained? that is documented and implemented.
program.
Plater shall have preventative maintenance system Filters are verified via the frequency
3.5 Are filters maintained? X
that is documented and implemented. specified on the process control plan.

For hydrogen embrittlement Uniformity survey must show that ovens were tested
relief ovens, are temperature both empty and with a full load. Parts must come up
3.6 N/A X
uniformity surveys performed to temperature within one hour of entering oven and
yearly? meet temperature tolerance specified by customer.

For hydrogen embrittlement


Plater shall have preventative maintenance system
relief ovens, are
3.7 that is documented and implemented. N/A X
thermocouples checked
and/or replaced quarterly?
Plater shall have a defined drying process to
Is there a drying/curing The drying process is included inside the
3.8 adequately dry parts. Process to include control and X
system in place? control plan of each process line.
verification of temperature and time.

© 2012 AIAG (Automotive Industry Action Group)

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