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  • CQI 12 Avaliação de Sistemas de Proteção

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    124 visualizações61 páginas

    CQI 12 Avaliação de Sistemas de Proteção

    Enviado por

    Roberto Bento
    avaliação de sistemas de proteção.

    Direitos autorais:

    © All Rights Reserved
    Baixe no formato PDF ou leia online no Scribd
    Sinalizar o conteúdo como inadequado
    de 61
    AIAG 2m CQI-12 Automotive Industry Action Group Special Process: Coating System Assessment AIAG cal ABOUT AIAG Purpose Statement Founded in 1962, AIAG is a globally recognized organization where OEMs and suppliers unite to address and resolve issues affecting the worldwide automotive supply chain. AIAG'S goals are to reduce cost and complexity through collaboration, improve product quality, health, safety and the environment; and optimize speed to market throughout the supply chain AIAG Organization AIAG is made up of a board of directors, an executive director, executives on loan from member companies, associate directors, a full-time staff, and volunteers serving on project teams. Directors, department managers, and program managers plan, direct and coordinate the association's activities Under the direction of the executive director. AIAG Projects Volunteer committees focus on business processes or supporting technologies and methodologies. They conduct research and develop, publish, and provide training on standards, conventions, standard business practices, white papers, and guidelines in the areas of automatic identification, CADICAM, EDIelectronic commerce, continuous quality improvement, health focus, materials and project, ‘management, occupational health & safety, returnable containers and packaging systems, transportation/customs and truck & heavy equipment [AiaG PUBLICATIONS An AIAG publeation rftecs a consensus of those substantial concemed with ts scope and provisions. An | AIKG patheaton intended asa gue oak the manufacturer, to consumer and the genera pubic. The | éestence a an AIAG pubicaton does net in any respec preclude anyone rom maar, marketing, | purchasing. or using products, processes, procedures hot conformng othe publication | CAUTIONARY NOTICE | AIAG pubtcatons ae subject o periodic review and users are cadoned ooblin the lalestedtons | MAINTENANCE PROCEDURE : ‘Recognising thal this AIAG publication may nt cove al ctcumstancos, AIAG has established @ maintenance procedure Ploase fer to ho Maintenance Reques! Forma the back of ths document f Saba request | Published by. ‘Automotive Industry Retin Group "26200 Lanser Rond Suite 200 ‘Southiela Michigan 46033 Phone: (248) 358-3970 «Fa (248) 250-2259 APPROVAL STATUS The AIAG Quatty Steering Commitee and designated stakeholders approved this dacument for publication on August 1, 2007 AIAG COPYRIGHT AND TRADEMARK NOTICE: The contents ofa published matonals are capynghted by the Aulomotve Indust Action Group unlos otherwise indicated CCopynght isnot clasned as fo any part of an orginal work prepared by 2 U.S or state goverment officer cr employee: a8 pt Of person's oficial dues All nghts are preserved by AIAG, and contont may not be aterod or disseminated. published, or tasters Im par of such contert The wermation 1s not fa be sold in part or whale fo anyone within your organization of to anche company Copyright nfangemant isa wolaton of federal law subject o cna! and eel penaties. AIAG and the Automotive Industy Acton Group ace reaistoned service marks ofthe Automotive Industy Acton Group. 2007 Automotive Industry Action Group cal-12 Special Process: Coating System Assessment Version 1 Issued 8107 AIAG & Automatve Icusty Acton Gop ac cai-t2 AIAG a Spec Process: Cong Sytem Assen FOREWORD Automotive Industry: Action Group (ATAG) comimitiees are made up oF volunteers from member companies in the automotive industry, The Work of preparing process audits is done by AIAG technical committees The main task of technical committees isto prepare Automotive Standards and System Requirements Draft documents adopted by the technical committees are circulated to the Steering Committee for review ion of the documents requires approval by the Quality Steering andl consensus approval, Public: Committee. ‘ommintee would like to acknowledge and thank the following individuals and their clopment of this document The Quality Steeti companies who have contributed time and effort to the de CQl-12 Special Process: Coating System Assessment Version 1 Issued 8107 ACKNOWLEDGEMENTS Core Members: Steven Kwong ~ General Motors Corporation Gregory Lobo ~ Ford Motor Company Brian Lowry ~ Curtis Metal Finishing Company Michael Pawlyshyn ~ General Motors Corporation Murli Prasad ~ General Motors Corporation Gordie Schafer ~ PPG Industries Larry Xu ~ Ford Motor Company ‘Supporting Members: Jim Aide ~ The Acadian Group Jamie Brooks ~ The Magni Group Ron Doran ~ Henkel Corporation Albert Gelles ~ DOrken USA, Tim Kittler— PPG Industries Jason Tylenda ~ Henkel Corporation AIAG Autratve instr Acton Gro AIAG earn ene err TABLE OF CONTENTS ABOUT AIAG FORWORD. ACKNOWLEDGEMENTS .cccsorseninnnnannen — e : INTRODUCTION 1 SCOPE, LU GENERAL 1.2 APPLICATION 2 THE COATING SYSTEM ASSESSMENT PROCEDURE. 3 SPECIAL PROCESS: PLATING ASSESSMENT INSTRUCTIONS FOR COMPLETING THE COVER SHEET. SPECIAL PROCESS: COATING SYSTEM ASSESSMENT COVER SHEET. B INSTRUCTIONS FOR COMPLETING SECTIONS 1-2 SPECIAL PROCESS: COATING PROCESS ASSESSMENT FORM: is JOB AUDIT... INSTRUCTIONS FOR COMPLETING THE JOB AUDIT 25 JOB AUDIT FORMS APPENDIX A ~ PROCESS TABLI carne AIAG Specia Process: Costing System Assessment p Version 1 Issued 8/07 Autom inutry Aation Grou INTRODUCTION General ‘The work of preparing CQI-12 Special Process: Coating System Assessment (CSA) was carried out through the ALAG Coating Work Group. These coating requirements are complementary to customer and product standards. The CSA can be used to assess an organization's ability to meet the requirements in this assessment, as well as customer, regulatory, and the organization's own requirements. The CSA can also be used between an organization and its suppliers In the CSA, the word “shall” indicates a requirement for purposes of the self assessment. Failure to meet the requirements results in an assessment that is either “Not Satisfactory” or “Needs Immediate Action” The word “should” indicates a recommendation, Where the term “such as” is used, any suggestions given are for guidance only. Process Approach The CSA supports the automotive process approach as described in ISO/TS 16949:2002 Coating System Assessment Goals ‘The goal of the CSA is the development of a coating management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain. ‘The CSA, coupled with an intemationally recognized quality management system and applicable customer-specifie requirements, defines the fundamental requirements for coating management systems. ‘The CSA is intended to provide a common approach to a coating management system for automotive production and service part organizations. Assessment Process Ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to reexamine the continuing compliance with the CSA. Each assessment shall include a review of the organization's systems using the CSA. Successive Job Audits (Section 3.0 of this document) shall sample Parts from different automotive component manufacturers that require compliance to the CSA document ‘The assessment shall use the process approach to auditing as identified by the requirements of ISO/TS 16949:2002 ac AIAG & spac Paces Cong Systm Asm Assessor Qualifications Assessor(s) shalll have the following specific experience to conduct the COATING SYSTEM Be an experienced quality management system (QMS) internal auditor (for example ISOS 16949:2002, ISO 9001:2000), 2. Assessor shall possess coating knowledge, Evidence shall include 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 automotive quality core tools including statistical process control, measurement systems analysis, part approval, failure mode and effects analysis, and advanced quality planning ‘or is required to meet the above qualifications, the lead [ Note: If more than one asses | assessor shall be the person meeting the requirements in item #1 _ Other Requirements ‘The organization shall keep records as evidence of compliance to the requirements identified in the CSA. as well as all appropriate action plans to address any unsatisfactory ratings. These records shall be readily available for review by any customer requiring compliance to the requirements within this document. ee AIAG 2m ———— Version 1 Issued 807 Auteresve ncty Acton Group 1 SCOPE 1.1 General This document specifies process requirements for an organization or its suppliers performing applicable coating, which need to: * demonstrate ability to consistently provide product that meets customer and applicable regulatory requirements, and ‘* enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system. The Coating System Assessment is applicable to sites where customer-specified parts for production and/or service are processed throughout the automotive supply chain. 1.2 Application All requirements of the CSA are generic and are intended to be applicable to all organizations performing the coating operations addressed in this document, regardless of type, size, and product. Ten Process Tables have been developed and the appropriate table(s) is to be referenced during the assessment. The Process Tables are specific to coating processes as noted below: * Process Table A ~ Pretreatment — Aqueous Cleaning ‘* Process Table B — Pretreatment ~ Mechanical Cleaning * Process Table C — Pretreatment ~ Phosphating * Process Table D ~ Powder Coating Flectrocoating * Process Table F — Liquid (Spray) * Process Table G— Dip/Spin Coating * Process Table H ~ Autophoretic Coating ‘© Process Table I~ Convective Cure © Process Table J ~ Equipment © Process Table ‘These Process Tables contain requirements for: 1. Process and Test Equipment 2. Process Monitor Frequencies 3. In-Process/Final Test Freques 4. Test Frequencies The Process Tables specify the process parameters and the frequencies for checking process control parameters and parts, as well as periodic maintenance requirements. The Requirements and Guidance in the CSA form will notify the assessor when to refer to the Proce ac AIAG gale 2 THE COATING SYSTEM ASSESSMENT PROCEDURE Obtain current copy of CQI-I2 Special Process: Coating System Asseysment from AIAG. 2 Identify all coating processes to which CQL-12 Special Process: Coating System Assessment applies (see CQI-12. 1.2), Record these processes an the CSA 3. Complete the CSA. determining the level of compliance. A minimum of one job audit (Section 3) shall be performed during each assessment m and determine corrective action, including root cause ive action(s). The corrective 4 Adress each atisfactory analysis and implementation of the corresponding cor action(s) shall be completed within 90 days, Records of the corrective action, ineluding. verification, shall be maintained 5 “Needs Immediate Action” requires immediate containment of suspect product. Address each “Needs Immediate Action” item and determine corrective action(s), including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. 6 Assessments shall be conducted annually unless otherwise specified by the customer. causa AIAG a ‘Version 1 Issued 807 Automate Industry Acton Group 3 SPECIAL PROCESS: COATING ASSESSMENT INSTRUCTION FOR COMPLETING THE COVER SHEET. ‘COVER SHEET FORM, INSTRUCTIONS FOR COMPLETING SECTIONS 1-2 SECTION I: MANAGEMENT RESPONSIBILITY & QUALITY PLANNI 3 SECTION 2; FLOOR AND MATERIAL HANDLING RESPONSIBILITY. 21 INSTRUCTIONS FOR COMPLETING THE JOB AUDIT SECTION 4: JOB AUDIT 10 CcaQli-12 Special Process: Coating System Assessment mpleting the Cover Sheet 9 ne of the facility being assessed One form shall be used for each facility, The facility may have several buildings or physical locations in the same general area. I'thore isa separate management team (Quality Manag. Coating Specialist) or different management system, then these locations shall be considered as separate facilities and ed: P.O, Box numbers may be given as Address: The street address of the facility being additional 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. ‘The fax number of the facili Fax Numbe Number of Coating Employees at this Facility: The number of employees, salaried and hourly. associated with the coating operation at this f Captive Coater (VIN): Enter “Y" if this facility coats components for their own company. Enter ” if the company does not coat any components for their own company ilty ‘Commercial Coater (¥/N): Enter “Y” if this facility coats components for companies other than their own company. Enter “N” if this facility does not coat any components for other companies, Date of Assessment: Enter the date(s) of the assessment, An alphanumeric format shall be used to avoid confusion with different numeric formats. Example: May 3 ~ 4, 2006 Date of Previous Assessment: List the date of the previous CQI-12 Special Process: Coating System Assessment of this f Type(s) of Co: + Place a checkmark to designate the coating process(es) performed at this facility, This information determines the appropriate Process Table that shall be used during the assessment, Processes not listed on the cover sheet are not part of the Coating System Assessment Current Quality Certification(s): The coater shall list their current quality certifications, e.g ISO'TS 16949:2002, ISO 9001:2000. Certifications may be from 3rd party sources or customer quality 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 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-assessment shall be given here, and the appropriate Question(s) from Sections. 1 = 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 Not jory Findings” shail be modified as appropriate Satis address(es). if Personnel Contacted: List the name(s). title(s), phone number(s), and e available. of the principal participants from the coater’s organization, 4 poe AIAG Spocin Process: Costing System Assessmvent | Version 1 Issued 8/07 Autertve Industy Acton Grow 14. Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), if available, of the auditor/assessor(s) 15. Number of “Not Satisfactory” Findings: Enter the number of “Not Satisfactory” findings observed during the assessment. 16. Number of “Needs Immediate Action” Findings: Enter the number of “Needs Immediate Action” findings observed during the assessment. 17. Number of “Fail” Findings in the Job Audit(s): Enter the number of “Fail” findings observed 12 from the job audit. ac \ at AIAG EE [Special Process: Coating System Assessment Facmy nae — — fares = = [Prone Nomar - Fipete of Cong Processes at hs Fac [Fncnonber =< recess Table A T —- [aqueous Claaning nina Contng Cnpioyees as Fae Process Tabe 8 IecharcalClaning capioa Came Process Table C— [earmeritCoster (VT Pressing Process Table D [para Aesnsamant J Powier Coating rocens Table € [Dae a Previous Assos Etecvaccat acess Table F pi roceaa Table © piso rocess Table H Propose rocess Table] orvecine Cure Process Table 7 [Equprent rant Guay Contcanonsy te of Re assassin roca _ [Personnel Contacted: Name: [Rudiora/Assesors [name (umber of Wot Satetactony” Findings [Ramber of "Needs Immediate Action” Findings Ramer oT Fair Findings inthe Job AUG) 13 oe AIAG 2» Version 1 Issued 8/07 Autoratie indusey Aton Group Instructions for completing Sections 1 and 2 Sections 1 - 2 contain questions and the requirements and guidance for each question, The Sections are: Section | ~ Management Responsibility & Quality Planning Section 2 — Floor and Material Handling Responsibility. ‘The assessor shall assess the coater’s compliance to Sections | and 2 by comparing the evidence presented by the coater to the requirements listed in the “Requirements and Guidance” column, [ NOTET In the “Requirements and Guidance” column, the word “shall” indicates 4 requirement and the term “such as” indicates that any suggestions given are for guidance only. | NOTE 2: The “Requirements and Guidance” column will indicate o the assessor when the Process Tables are pertinent to the Questions. When the Process Tables are pertinent to the Question, the assessor shall assess the ‘coater's compliance to the specified section(s) in the Process Tables. place a checkmark in the “N/A” Assessment column. If the observed evidence is in compliance to the question, the assessor shall note the evidence in the “Objective Evidence” column and place a check mark in the “Satisfactory” column. If the observed evidence is not in compliance to the question, then the assessor shall note the non-compliance in the | "Octve Evidence” clu nd place a cack man th -Na Satisfactory” column, | NOTE 4: Where nonconforming product is identified in the assessment of a given question the assessor shall place @ check mark in the “Needs Immediate Action” (NIA) column. NIA requires immediate containment of suspect product. 14 ac CcaQl-12 Special Process: Coating System Assessment ver fayouroep 29 ys Sebueys ssaz0% ye uoneoyvep su, paanba: 5: seb vey seezen Buyuuerg Gueno pus Ayyaisvodsey juawebeuey - 5 uonses ‘vorseysnes }yin soup na ennosia soueping pur rwvewaynboy wopsenp, uonseno (marnsa0g 184 |12U9Q) JUoWSsassy WaSks BuNLoD :ssa001q [e|oadg, 15 Automate uty Aeon rou AIAG» ‘Special Process: Coating System Assessment Version 1 issued 8107 CaQl-12 ~weer pe LL. jo 90 a sjseconut yes vonene | vans a esusseco] wou Bu odo swan s0t s2uapina on20/@0 soueping pue siwewnynbes onsen, (mo}A19AQ Ayt1984 |e10uU09) UaUISsessy WaSKg BUNLOD :sseD01q jeIeds, 16 sssment CcQl-12 Special Process: Coating System saisayozeuurea| ue 04 ‘oj s2u09| ‘iLs¥ Ovtv ays dur ‘oowessnes [vin s2uspig ennosIG0, soueping pue syusuaynbey wwonsa00, a onsen (movseng AaI119e4 e12U99) uaWssossy Wayshg BuReOD :ss00044 jelD0dg 7 Autores nt Acton Group Special Process: Coating System Assessment Version 1 Issued 8107 CcaQl-12 6 " our’ no lacie eao*S| iovousues [ym] souspia enoelag ‘eourpino pus uennboy wopene Farad (moynsoag Ay|9e4 [e10U0D) jusussessy Worshs BuNeoD :sse001d leloadg 18 x = 3 3 < 3 2 8 ¢ & S | ‘coroeisues {vi soueping pu syueweynbey {sey (mayueng Aujise4 le1ouen) juowssessy waishs Bunecd :sseo0ig jeloads 19 Autsaive Inc Acton Gu AIAG a sseror Bune0> oa Toy sreypeu Aaoroejsnes. [vm ‘s2uaping an20fa0 s2ueping pur siuewsybo onsen peawon SOON tne 2 onsen (motnton fuioe4 les0u99) uewssessy weyshs Buneod :ss09014 jeloods Special Process: Coating System Assessment Version 1 Issued 807 cQi-12 20 caQl-12 Special Process: Coating System Assessment Version 1 tes ‘Aujiqysuodsoy BunpueH [eueieW pue 1001] -2 UONDOS. s2uepin9 pue suuswoujnbey onsen Taquon onsen) (moinseng Ayt}oe 1e10U99) uauissassy woyshg BuNeOD :ss90014 jeoadg 2 Aueetvencty Aston Group AIAG Special Process: Coating System Assessment Version 1 Issued 8107 CQi-12 ‘Spa 9 Fonda 10 See 22014 30} eparonuonpue pawouncos] pur es td sued pmypeds pes ued o£ Prwoursep poy jesoyes seuerdaeu pen ® sz auerss voranpeg og 1 onpoid Basan] tou pe iuowarow waved) 92 ua pu sy Bune Kasout yo se neutrons pourra] Sueno 09 TY aooommrs| ompeumet | ion | Gomusnes lyn uepina 2an2f40 s2ueping pue suewsyboy onsen 500K (mor1en9 Auy}9e4 [es0Ua9) juoUssessy Wa}SKg BuNeOD :sse00lg je}Deds 22 CcQl-12 Special Process: Coating System Assessment Versor Ga | o { | way — To arepowiy |MPPSISMES) gosoeyones [vin #2uspina 2anselao, 1 T ‘Soon wen ueping pue siuswozinboy | wonsono po r 23 Agoratve Indust Action Group AIAG Special Process: Coating System Assessment Version 1 Issued 87 caQl-12 power uourdnbe ys ompedsi] FE sae, sso 1.564 “sojaes sooo1g u paynads se suyod| ‘a ges spusnbL pur pansner sound) 217 uoeayeodsjonace yo ar reo ogo sued vonpees pauaunaop er ora ex vepeuy =220N Tsay T- (morn12A9 Auyioe4 [eeue9) juoussessy wia}shg BuReod :sseo0dg leID0ds, seaU0N ‘Aovoessnes lyn s2uap 13 onnselao, eoueping pu siwowsunbey, fea © 24 & 1-12 AIAG spec Process Conta Syst Anes ting the Job Audit The organization iso complete a minimum of one coating part job audit during each assessment, This should be done preferably on a part identified for one of the customers requiring compliance to this document, More part job audits may be done iftime permits. Preferably. safety or eritieal parts should be audited. This may not be easily determined with fasteners, especially ifthe Fastener manufacturer does not identity the end customer (auto manufacturer, tier one, ete). Its recommended that the job audit be Instructions for com, performed at the end of the coating system assessment, The job audit is not the only or main focus of the CSA. The other wo sections on Management Responsibility and Quality Planning and Floor and Material Handling Responsibility are equally if not ‘even more important. The job audit of one part, one coating process. is not sufficient to use as a basis to complete the other sections of the complete CSA. The job audit is a compliance type audit‘review of a specific part and its related paperwork and processing, including coating equipment and processing records for that job from the beginning receipt of «2 part through processing in the coating operation and inspection to packaging, Paris shall be taken from the shipping area at the dock or the end of the coating operation. If an automotive manufacturer's parti not available or identifiable, then parts from other customers requiring compliance with this document shall be used for the assessment. The specific coating processing parameters (applies to 3.7 in the Job Audit) that are required in the job audit shall be added to the job audit form. This can be done by reviewing the customer specitication(s), the Control Plan, the FMEA, and the floor work!job order. Each processing step shall be reviewed for proper production records/compliance/inspection. These steps can be compared to those in the Coating System Assessment for the actual jobicoating process being reviewed for compliance. 25 Autemotwe inuty Acton Group AIAG ‘Special Process: Coating System Assessment Varsion 1 Issued 8/07 CQl-12 ez zz oe oF re ue Jo 20uep9 pajuawnaop avn si] 5 vz ez ve zz ve ot sou 01 parea Ge st 24 20) suoneoyioads soworsno] ze on 0doid 2 2x64 23609 etn Soa] a ~ wn ei payenb fq pawioped et Tonvoo "yang ‘Suwueys Aen) FE Ey paoueape ple maines eave 3 (eaeohe owen) | van emurect ocean woueinbes [#0 YEO] worsen umveor | ruomng ‘onrpueo rensoy See euro 20 9wo;sng poveiee " st w0 tos nboy 6unt09 re uonduoseg wed SSeS inti 28109 doug sowoysng aaREPT OF ‘mayne Yonpoid Pousiuls - upny gor - ¢ uoRoeg 26 CQl-12 Special Process: Coating System Assessment ee | — toes aid oa ovaboy | weno v9 vonenuioog see 70 1 46 —_ mauuneog exe | eum sovoucnng —|° pom ance cane! sts otsountioy sunt09, trot 2599 v0 ‘marnew jonpoid poustuls pny gor - ¢ uoH‘oaS ar CQi-12 AIAG Special Process: Coating System Assessment Version 1 Issued 8/07 ‘Autoraive ncsty Acton Coup Fae SSUES voTDaTes| TaUeRB 16 FousnbeH Ts DOWN TTOL| eoidde 1) BIeu wowmaw;| stoipty awowoynboy| © SET TUR 1 TouoTbay er} zee Toe (SO ATENS SUES SIE HORST We Hen pu mojeq ueUreHMss Yoee 1 WewWerNbe1 Yoed you SMW Syed abe lonsedeuyonpaxt Be ona oeds Guneo0 oui Aa peuluusi9p sjueweanba1 ous 30 U0 ane Aes Wed Yoe st voveedsuronpond ot TwaTaHn ay vines] (eouepna exela0) woweunboy #uons=nD ¥SO n/nea | (eaveen en Uonewauina0g eouesqoy |. MONSHNEE =n Leogsano pny aor oo) 1sse nypuOD rerioy seater rewsiu 0 sowoisog ereren ‘Swowennbow Buneo9 _maqnoy jonpoig PaUstUl4 - pny Gor ¢ UORIeS. cal-12 Special Process: Coating System Assessment AIAG = DoRRTID_TS 94] aig Mowanbou| See IN es [sea wawannbos #uDusen WSO ewsoqu 0 saworsng aieiou ssorsono pry aor f# vowsano, jonpoid Posiuls- upnY aor ¢ uoHoOg 29 CcQi-12 AIAG» Special Process: Coating System Assessment Version 1 Issued 8/07 Automatve inausey Acton Group ToReDHUAS| sawoysng, a0 eee “Tt “voqesy eds] & es 3) euosuewg wwewainboy) 22 as oan a sovenocdy ueusnooy] 258 vasa] p13 00980) | woygoe emmy | _mmummina |wuomeroveo) sano pyar [poms rina | “voupworeney” | MmaumeD ean | autem |e nso swowosnbou Bunee9 soqoeeg a TO so qui ie taunt rao deus ‘moynow Yonpord PEUSIUIA - UPNY Gor ¢ uoRI9g CcQl-12 Special Process: Coating System Assessment | | a bt - | | | | eve ae ue ove - 7 4 ee | e taps ssa00.d ajeudasdde asap ° | ze ‘os sso andor | —_ Ph | = GINS TOSSA ToT (eavapin3 aanjasigo) : mee 2013 NEO) | ogeneuoot eh vonseno wpny aor | uensoag L [219019 (ous) aon RRUSBTaOT AIAG ‘moqnoy jonPodg PaYsiULy - UPN Gor ¢ YoRDeS 31 Auten ineuteyDeson Gro. AIAG 2» I Process: Coating System Assessment Version {Issued 807 cal-12 Spec TPT] fusdosd soueuos Su 804 1704 0) fuadous syed ow a1) “sjueurasinbey Bu JOUIE|UOD JO aBisu Jeno poyDed sued ‘2jduex0 20) su0d paxil sz 01 pabey2ed syed oy} payne! stuswounbos Bubermed oy SSUES wines 3) (ouopi'a eaioaiao) ‘Wompuod renioy lwonson0 pny gor ‘molAoul Yonpoid PoUSIUIA - PRY Gor - ¢ UoR2eg 32 AIAG & APPENDIX A - PROCESS TABLES PROCESS TABLE A: PRETREATMENT (AQUEOUS) PROCESS TABLE B: PRETREATMENT (MECHANICAL), PROCESS TABLE C PRETREATMENT (PHOSPHATING) PROCESS TABLE D: POWDER PROC! BLEE: ELECTROCOAT PROCESS TABLE G: DIP’SPIN. PROCESS TABLE Hi AUTOPHORETIC. PROCESS TABLE I: CONVECTIVI PROCESS TABLE J: EQUIPMENT CURE. Special Process: Coating System A CcQl-12 sessment M xo wo 41 43 33 CcaQl-12 Special Process: Coating System Assessment Version 1 Issued 8107 AIAG veomotve eutey Acton Gru PROCESS TABLE A - Pretreatment (Aqueous) [Atl requirements given below are subordinate to customer specific requirements. [The customer may have additional requiroments, e.g., inspection testing, greater frequencies, etc, When performing, the job audit, the auditor shall verity coater is conforming to customer requirements. Related tem # | cosa tuestion # Category/Process Steps Controt Monitoring "AQUEOUS CLEANING PROCESS (Alkaling| 10 ‘or Acid) [There shall be an incoming part assessment . =a Aa 14 eee var onan Per Control Plan Por lot 20) Cleaning Bath(s) [The folowing checks shall be performed fat 2-11 | during production NA Per Control PlaniLog Sheet 22 211 |PressureiAgitation ‘AutomaticiManual| Pe" Control PlaniLog Sheet E (hilt minimum) 212 iA Per Control PlaniLog Sheet 23 211 [Temperature AutomaticiManual| P& 0 Shes! (shit minimum) 212 +4 2 16 Per Control PlaniLog Sheet A248 2h htm Automasicnania oe or oo 22 14 16 rnuat | PAF Conttol PlaniLog Sheet 25 24, [Chemical Concentration Automate manual oe cay 212 i Per Control PtaniLog Sheet 426 2.11 [Impurity Content (e.9. acid split Manual er Con og a (shit minimum) aor 2.11 [There is @ dump schedule for cleaning baths. Manual | Per Conta! Plan/Log Sheet 34 ac AIAG a caQl-12 Special Process: Coating System Assessment PROCESS TABLE A - Pretreatment (Aqueous) Alt 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, Ralted tem [cae Catogon/Process Stops Control Monitoring 3 Rinse Bai) 7 ft tioning cect sha be peared aot an |during production: a Per Control Plan'Log Sheet ABZ an |Pressure/Agitation ‘Automatic/Manual | Per Contr 9 (ian iat bi 4 Per Control Plan/Log Sheet a3 211 |remperatue AutomaticManual | Pet Control Plavtog Sheet ‘iit rr) 21 7a i er Contol Plano Sheet wea | 8 frame Asamatcmanus| Pr Canto Pann zi 4 Per Control Plan/Log Sheet 38 an Impurity Concentration Manual con eet aa ‘ist minor) 4 Per Control Pian/Log Sheet 438 211 |overtiow Rate Automatianual| Pet Conkel Panitoa 242 ‘s 137 |_211 [thew aumpccheaue for noes nwa! | Pe Cone Pani.og Set lees a viuatapecion fg, watr Bey contol Patan Soa n38 714, eter each post clearing rinse bath where anwar} PerConvel Panton Sh lpossible. (not applicable for bulk) s! 14 frees ana ns. sal be mentored or Per Cont tantog Shea 138 ant Jpresence of bacteria. (for plastic substrate) Manual (lishift minimum) “aortas = Coron ir conconaion er Garza Pntcog Sa A310 2a lis checked_ {i applicable] ‘AutomaticiMangal (Wishift minimum) 35 CQli-12 ‘Special Process: Coating System Assessment Version t Issued 807 AIAG Adore nasty Acton PROCESS TABLE B - Pretreatment (Mecha al) |All requirements given below are subordinate to customer specific requirements. [The customer may have additional requirements, e.g., inspection testing, greater frequen: 8, etc. When |performing the job audit, the auditor shall verify coater is conforming to customer requirements. Related ttem# | csa CategoryProcess Steps Control Monitoring Question # 7, "ABRASIVE BLAST PROCESS [There shall be an incoming part assessment ‘er Bit 14 Tree anarionn Per Control Pian Perot oo aii [Refolowna checks sabe perormed dung Ta 16 Per Control Plan/Log B13 211 [Abrasive media flow Automatctanual | croc font anne 242 14 16 m Per Control PlaniLog Bia at [Nozze air pressure AutomaticiManual | cree ayant anime) 212 74 16 Per Control PlaniLog B15 2 [Dwettime AutomatioManua | roar afi mn) 232 4 Per Control PlaniLog B16 2.11 [Dust collector etficiency/alr low Automatic | ee orit nae) 212 ay Per Control PlaniLog B17 2.41 | Working mix AutomatioManval | cross ahi sano 212 14 Per Control PianiLog B18 211 [Setface cleanliness is checked after process. Manual — | roe archi osmmen) J, |urface profile is checked after process (if B19 an cleat Nel eel Manual Per lot 215 feppicable). ac AIAG» Spec Process: Costing Sytem Acre PROCESS TABLE C - Pretreatment (Phosphating) anrecuemens gen btw ar subornae to customer pect equrements in customer may have atonal requirements nspecion ttn, rater oquencies, te, When peoing te Jo ava th ater sha voy costars conforming to esloma ogame | tema Related | categoryiProcess: or mnitoring rut [gat | caeporProces Steps contol Mentoring [40 Conversion Coating cs [ve (Reeseoumongeat | reciwctran | Pe a Tirso Conlon Apps) Setar ie tong choos sib pared fa Per Conta PaniLog cz2 | 21 ressuengtton AtonaeMon a 28 ant [Time ‘Automatic!Manual | seet (tisha minimum) 4 Per Control Plan/Lo¢ c2s 211 |onemca! Concentration Automatcntanuai| Per canal anton, 242 " cas at |conditioner. Manu “Manufacturer's Guideline | 30 Conversion Coating Bath _ } ot 2.11 |auring production: _ 7m Pe CooraPantcy ca2 | 21 femweiepinen tonal] ghecuna Pang, ie a an soot a cat 2a [Time ‘AattomaticrManual | Seer (shift minimum) face ron Content pH Aeclrtr Arau|Afomavctnua] Pet ntl Pang eee, | loci coated) ‘AutomatioManda!| sheet isi minimum) [Coating Wear ™ ‘Sheet (1/shift minimum) cas 211 |onstat size apptcabey Mana Por castomer ie " 37 CaQl-12 Special Process: Coating System Assessment Version 1 Issued 807 38 PROCESS TABLE C - Pretreatment (Phosphating) AIAG 2a Audorrtun incusty Acton Group [Al requirements given below are subordinate to customer specific requirements. [The customer may have additional requirements, e.g. inspection testing, greater frequencies, ete. When Jperforming the job audit, the auditor shall verify coater is conforming to customer requirements. Related tom |egsRlated | categoryProcess Steps Control Monitoring a Rinse After Phosphate he foowing checks shal be permed cd ant [during production: 4 |impurity Concentration (¢.g. Titration, Per Control PlaniLog ad att Conductivity) Manual ‘Sheet (1/shift minimum) 212 if Per Control PlaniLog cas 211 |ressugtaton Automatctansal} Per ContolFlentog, 212 va 1s Pet Control Pan.og aa an [rime ‘Automatic(Manusl | siege (1/shif minimum) 212 ; Per Chemical cas 211 | heres dump schedule fo rinses Marvat —|aganu eer cnemiel 3 ‘Seal Rinse Ihe folowing checks sha be permed od an |during production: Wy Per Control Pian/Log cs2 2:11 |Pressure/Agtaton Automatcntanual| Pet Conte Panag zie _ 14 16 bine stomatcntanuat| _P2* Cantal Penf.og 88 Qn ir AutomatioMandal) eet (shift minimum) 212 7 4 Per Control Pian/Log cs 2:11 |enemica! concentration AvtomaticManua] Pe, Contel Manica, 22 | i wy perature applica 4 Per Control Planttog o5s | 211 Tempe tapes ‘AomatiManual] ret Cantal Manon | Per chemeat cs 2.11 | There is 2 dump sched for seal nse Mama — | yan eer ememeal so Diy OAH Applcabie] 14 I teomperatr is montored and Per Control Pan.og cas an Automatic 211 [contd ‘ sheet (fst mine) 1:4 [There ea procedure to ensure dryness of a coin 2a [parts prior to susequent coating. oe Each L ac AIAG cola faomeras ma etn Rate He Version 1 issued 807 PROCESS TABLE D - Powder [ri recvirrents given below are subordinate to customer apace raquiemants ne customer may have eddiona requirements ©. lnpection esting greater requences, ec. When performing the ob au the fests ener cooing ennerearenens tem # Related cat fProcess Steps: Controt “Monitoring CSA Question # tego’ tees 0 rm ower Part Appiation or TA Tran re SoevaT ong deg over ceanineaT STAGE | Par Con aay 211 fate, prs tenting poe toot " hoo! hos za Powder Booth and Equipment bat 211 [Tho temporaturo of parts entoring ho coating booths moriores. | AutoraticManua’ | .p&r Conte Pang 2a 14 18 |rneconseyors operating athe proper ine soos (no ab somane | Pet Convo! Panton pee J 77 fovwement of contact between pars. as Sheet (tisha) aa ore | ah fire gouas choc sing 9200 at again mar fsston | paemmasanann Poem Penton imagen estan) ‘She (eminem zu 4 i he alr dryer and fer are on main compressed air line ‘AutomaticManuat | Pe Canto! laniLog & 0 zi [The aranerana " ‘Sheet shit nino) : ae 14 an “ ons | Pe-Cenre! Panton 025 | 317 re both mpeatie and hui ars ced. Monasi | eurConraPlnee aa i : |_| srerconrar monte 826 | 211 frmareainn isonet here tomar | oerCowel tna 7 aie [Tse eotar is dean tional. jomatic*Manual | Pet Corll PlanLog oe 2a he rotory sive ts clean ane! opera Aaomatio ‘Sheet (1/shitt minim) 312 o28 | 21 fhe powsortow monte “puomancdtanu | Pe" Coe Planiog 2 penser reno senenene tears | shoot (shi mramm) tf Per contol Panton 023 | 211 |rnoventassit ak pressure chkos anus | Per Canvo| Panton 2 Sheet eh mmm) 0210 | 211 |rmoventon oud hppa i chaches Mamint | Pe Contes Plante bn + 0211 | 287 trneracam sev operating sonny Momus | Per Canta| Panton an 39 CaQl-12 Special Process: Coating System Assessment Version 1 Issued 8107 PROCESS TABLE D - Powder JA requiroments given below are subordinate to customer specie requirements AIAG» Aunt cus Acton Group [Tie customer may have addtional requirements, 2.9. inspection testing, greater frequencies, ete. When performing the Jb aud, the Javxitor shall very coater is conforming to customer requirements | __ Relates rocess St control onion emt | goat@lted CCategoryProcess Stops Contre! Monitoring 317 [at guns ae operational i | _Pecconros Plantos oan a uns are operational arin good rep Maniat | per ConrosPlanog 212 1 117 |The vont in th food pumps andthe pick up tubes inthe hopoe"| span pu schadule cx 211 forecneckes Por PM sched 212 34, |e toos noses arw checked io oncure that thoy have no excessva| Per Contr Planog bate ain Manual 311 Ioan and kinks, Shoot (ay menu) i Per Cont! PlaniLog 0215 211 |The vignrectsim ratio is checked. eed pressure) Marva! i coal ea) 20 Sheet (shi ) 216 11 ne static pressure gauges on priory and i fie onal econ Eee ai static pressure gauges on primary and final ters are checked. Manual | 681s ht marimar) 212 7 ait vance o gas exting both amas | Pat Conta! Piant.og cx 212 |APearance of pars exting booth is checked Sheet (par how) 218 0218 2.11 [The power suply and atomizing al pressure ate checked Manuar | pee Cotesia. 242 eo “Cure (See Convective Cure Process Table) 40 oc & AIAG 2 PROCESS TABLE E - Electrocoat CcQl-12 ‘Vernon 1 Issue Special Process: Coating System Assessment ren farveaorements gen below ae uberis estome peli requirements rn customer may nav adtona eqsromens«g specton esting, reser reunite: When peroming he jo au Jrcsor san any cone cortorming coroner erent } cae | wet esa, GnesonProces Spe contot Wonton | [a8 recon Pa Appctn Par Appearance | | Sra Te nina pater pce canna Sean) Pataras Bnop ___2i1 [format in ane oer Sooo pr oar [za Elecrocoat Labortony —— Ce Co wa ceo | ae femsrer naar anareninsare paves Kiso. | yg 2 oe at ners Sa Tar em ir a ai aE YP Co PG leveane st ah any 3a eevee Tank car | nay [estate pends, sokteaen ones Lapaacnna] PX Coes Penton 312 __fotge are creche ant std fe Stet va 52 | 38 |onospontsaun checks utomatenenual| Pe" Comeleunten a 559 | 211 [unsomsievetos vist | Onno ir 34 fire worcinionaneamronme ower esi Ta gamantna)

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