Coating System Assessment CQI-12

CQI-12 Special Process: Coating System Assessment Version 1 Issued 8/07

Special Process: Coating System Assessment Facility Name: Address:

Phone Number: Fax Number: Number o" oatin! #m$loyees at this Facility: a$ti&e oater '(/N): ommercial oater '(/N): *ate o" Assessment: *ate o" Pre&ious Assessment:

Type(s) Type(s) of Coating Processes at this Facility: Process Tale A Aqueous leanin! leanin! Process Tale ! %echanical leanin! Process Tale C Phos$hatin! Process Tale " Po+der oatin! Process Tale # #lectrocoat Process Tale F ,$ray Process Tale $ *i$/,$in Process Tale % Auto$horetic Process Tale I on&ecti&e ure Process Tale & #qui$ment

urrent -uality erti"ication's): *ate o" .eassessment 'i" necessary): Personnel Contacte': ame:

Title:

Phone:

#mail:


Special Process: Coating System Assessment ($eneral Facility ,erie.) Assessment

Qestion mer

Qestion

/e0irements an' $i'ance

,ectie #i'ence

*A

Section 1 - anagement /esponsiility an' Qality Planning

11

1

Is there a dedicated and quali"ied coatin! $erson on site2

3o ensure readily a&ailable ex$ertise4 there shall be a dedicated and quali"ied coatin! $erson on the site 3his indi&idual shall be a "ulltime em$loyee and the $osition shall be re"lected in the or!ani5ation chart A 6ob descri$tion shall shall exist identi"yin! the quali"ications "or the $osition includin! chemical and coatin! no+led!e 3he quali"ications quali"ications shall include a minimum o"  years ex$erience in coatin! o$eration or a combination o" a minimum o"  years o" "ormal chemical education and coatin! ex$erience

*oes the coater $er"orm ad&anced quality $lannin!2

3he or!ani5ation shall incor$orate a documented ad&anced quality $lannin! $rocedure A "easibility study shall be $er"ormed and internally a$$ro&ed "or each ne+ $art or $rocess ,imilar $arts can be !rou$ed into $art "amilies "or this e""ort as de"ined by the or!ani5ation A"ter the $art a$$ro&al $rocess is a$$ro&ed by the customer4 no $rocess chan!es are allo+ed unless a$$ro&ed by the customer 3he coater shall contact the customer +hen clari"ication o" $rocess chan!es is required 3his clari"ication o" $rocess chan!es shall be documented

Satisfactory

ot Satisfactory

ee's Imme'iate Action




Qestion



*A

Section 1 - anagement /esponsiility an' Qality Planning

11

1

Is there a dedicated and quali"ied coatin! $erson on site2

3o ensure readily a&ailable ex$ertise4 there shall be a dedicated and quali"ied coatin! $erson on the site 3his indi&idual shall be a "ulltime em$loyee and the $osition shall be re"lected in the or!ani5ation chart A 6ob descri$tion shall shall exist identi"yin! the quali"ications "or the $osition includin! chemical and coatin! no+led!e 3he quali"ications quali"ications shall include a minimum o"  years ex$erience in coatin! o$eration or a combination o" a minimum o"  years o" "ormal chemical education and coatin! ex$erience

*oes the coater $er"orm ad&anced quality $lannin!2

3he or!ani5ation shall incor$orate a documented ad&anced quality $lannin! $rocedure A "easibility study shall be $er"ormed and internally a$$ro&ed "or each ne+ $art or $rocess ,imilar $arts can be !rou$ed into $art "amilies "or this e""ort as de"ined by the or!ani5ation A"ter the $art a$$ro&al $rocess is a$$ro&ed by the customer4 no $rocess chan!es are allo+ed unless a$$ro&ed by the customer 3he coater shall contact the customer +hen clari"ication o" $rocess chan!es is required 3his clari"ication o" $rocess chan!es shall be documented

Satisfactory

ot Satisfactory





Qestion


19

3he or!ani5ation shall incor$orate the use o" a documented Failure %ode a nd #""ects Analysis 'F%#A) $rocedure and ensure the F%#As are u$dated to re"lect current $art quality status status 3he F%#A shall be +ritten "or each $art or $art "amily or they may be $rocesss$eci"ic and +ritten "or each Are the coater;s F%#A;s u$ to $rocess In any case4 they shall address all $rocess date and re"lectin! current ste$s "rom $art recei$t to $art shi$ment and all ey $rocessin!2 coatin! $rocess $arameters as de"ined by the or!ani5ation A cross"unctional cross"unctional team shall be used in the de&elo$ment o" the F%#A F%#A All s$ecial characteristics4 as de"ined by the or!ani5ation and its customers4 shall be identi"ied4 de"ined4 and addressed in the F%#A

1

3he or!ani5ation shall incor$orate the use o" a documented ontrol Plan $rocedure and ensure the ontrol Plans are u$dated to re"lect current controls 3he ontrol Plans shall be +ritten "or each $art or $art "amily or they may be $rocesss$eci"ic and +ritten "or each $rocess In any case4 they shall address all $rocess ste$s "rom $art recei$t to $art shi$ment and identi"y all equi$ment used and all ey coatin! $rocess $arameters as de"ined by the or!ani5ation A Are "inish $rocess control cross"unctional team4 includin! a $roduction o$erator4 $lans u$ to date and re"lectin! shall be used in the de&elo$ment o" ontrol Plans4 current $rocessin!2 +hich shall be consistent +ith all associated documentation such as +or instructions4 sho$ tra&elers4 and F%#As All s$ecial characteristics4 as de"ined by the or!ani5ation and its customers4 shall be identi"ied4 de"ined4 and addressed in the ontrol Plans ,am$le si5es and "requencies "or e&aluation o" $rocess and $roduct characteristics shall also be addressed consistent +ith the minimum requirements listed in the Process 3ables


*A

Satisfactory

ot Satisfactory



Special Process: Coating System Assessment Assessment ($eneral Facility ,erie.) Assessment


1

1<

Qestion


Are all coatin! related and re"erenced s$eci"ications current and a&ailable2 For exam$le: ,A#4 AIA=4 A,3%4 =eneral %otors4 Ford4 and *aimlerhrysler

3o ensure all customer requirements are both understood and satis"ied4 the or!ani5ation shall ha&e all related coatin! and customer re"erenced standards and s$eci"ications a&ailable "or use and a method to ensure that they are current ,uch standards and s$eci"ications include4 but are not limited to4 those rele&ant documents $ublished by ,A#4 AIA=4 A,3%4 A,3%4 =eneral %otors4 Ford4 and *aimlerhrysler 3he or!ani5ation shall ha&e a $rocess to ensure the timely re&ie+4 distribution4 distribution4 and im$lementation o" all customer and industry en!ineerin! standards and s$eci"ications and chan!es based on customer required schedule 3his $rocess shall shall be executed as soon as $ossible and shall not exceed t+o +ees 3he or!ani5ation shall document this $rocess o" re&ie+ and im$lementation4 and it shall address h o+ customer and industry documents are obtained4 ho+ they are maintained +ithin the or!ani5ation4 ho+ the current status is established4 and ho+ the rele&ant in"ormation is cascaded to the sho$ "loor +ithin the t+o+ee $eriod 3he or!ani5ation shall identi"y +ho is res$onsible "or $er"ormin! these tass

Is there a +ritten $rocess s$eci"ication "or all acti&e $rocesses2

3he coater shall ha&e +ritten $rocess s$eci"ications "or all acti&e $rocesses and identi"y all ste$s o" the $rocess includin! rele&ant o$eratin! $a rameters #xam$les o" o$eratin! $arameters include $rocess tem$eratures4 cycle times4 load rates4 recti"ier settin!s4 etc ,uch $arameters shall not only be de"ined4 they shall ha&e o$eratin! tolerances as de"ined by the or!ani5ation in order to maintain $rocess control All acti&e $rocesses $rocesses should ha&e a +ritten $rocess s$eci"ication 3hese $rocess s$eci"ications may tae the "orm o" +or instructions4 6ob card4 com$uterbased reci$es4 reci$es4 or other similar documents


*A

Satisfactory

ot Satisfactory





17

18

1>

Qestion

?as a &alid $roduct ca$ability study been $er"ormed initially and a"ter $rocess chan!e2

*oes the coater collect and analy5e data o&er time4 and react to this data2

Are internal assessments bein! com$leted on an annual basis4 at a minimum4 incor$oratin! AIA= ,A2


3o demonstrate each $rocess is ca$able o" yieldin! acce$table $roduct4 the or!ani5ation shall $er"orm $roduct ca$ability studies "or the initial &alidation o" each $rocess4 a"ter relocation o" any $rocess equi$ment4 and a"ter a ma6or rebuild o" any equi$ment 3he or!ani5ation shall de"ine +hat constitutes a ma6or rebuild Initial $roduct ca$ability studies shall be conducted "or all coatin! $rocesses $er line as de"ined in sco$e o" +or and in accordance +ith customer requirements a$ability study techniques shall be a$$ro$riate "or the coatin! $roduct characteristics4 e!4 coatin! thicness4 corrosion resistance4 etc Any s$eci"ic customer requirements shall be met In the absence o" customer requirements4 the or!ani5ation shall establish acce$table ran!es "or measures o" ca$ability An action $lan shall exist to address the ste$s to be "ollo+ed in case ca$ability indices "all outside customer requirements or established ran!es

3he analysis o" $roducts and $ rocesses o&er time can yield &ital in"ormation "or de"ect $re&ention e""orts 3he or!ani5ation shall ha&e a system to collect4 analy5e4 and react to $roduct or $rocess data o&er time %ethods o" analysis shall include on!oin! trend or historical data analysis o" s$ecial $roduct or $rocess $arameters 3he or!ani5ation shall determine +hich $arameters to include in such analysis

3he or!ani5ation shall conduct internal assessments on an annual b asis4 at a minimum4 usin! the AIA= ,A oncerns shall be addressed in a timely manner


*A

Satisfactory

ot Satisfactory





Qestion


110

3he quality mana!ement system shall include a documented $rocess "or re$rocessin! that shall include authori5ation "rom a desi!nated indi&idual 3he re$rocessin! $rocedure shall describe $roduct characteristics "or +hich re$rocessin! is allo+ed as Is there a system in $lace to +ell as those characteristics "or +hich re$rocessin! is authori5e re$rocessin! and is not $ermissible All re$rocessin! acti&ity shall require it documented2 a ne+ $rocessin! control sheet issued by quali"ied technical $ersonnel denotin! the necessary coatin! modi"ications .ecords shall clearly indicate +hen and ho+ any material has been re$rocessed 3he -uality %ana!er or a desi!nee shall authori5e the release o" re$rocessed $roduct

111

*oes the -uality *e$artment re&ie+4 address4 and document customer and internal concerns2

11

3he coater shall de"ine a $rocess "or continual im$ro&ement "or each coatin! $rocess identi"ied in the Is there a continual sco$e o" the ,A 3he $rocess shall be desi!ned to im$ro&ement $lan a$$licable brin! about continual im$ro&ement in quality and to each $rocess de"ined in the $roducti&ity Identi"ied actions shall be $rioriti5ed and sco$e o" the assessment2 shall include timin! 'estimated com$letion dates) 3he or!ani5ation shall sho+ e&idence o" $ro!ram e""ecti&eness

119

*oes the -uality %ana!er or desi!nee authori5e the dis$osition o" material "rom quarantine status2

3he quality mana!ement system shall include a $rocess "or documentin!4 re&ie+in!4 and addressin! customer concerns and any other concerns internal to the or!ani5ation A disci$lined $roblemsol&in! a$$roach shall be used

3he -uality %ana!er or desi!nee is res$onsible "or authori5in! and documentin! a$$ro$riate $ersonnel to dis$osition quarantine material


*A

Satisfactory

ot Satisfactory





Qestion


11

3here shall be $rocedures or +or instructions a&ailable to coatin! $ersonnel co&erin! the coatin! $rocess 3hese $rocedures or +or instructions shall Are there $rocedures or +or include methods o" addressin! $otential emer!encies instructions a&ailable to 'such as $o+er "ailure)4 equi$ment startu$4 coatin! $ersonnel that de"ine equi$ment shutdo+n4 $roduct se!re!ation ',ee 8)4 the coatin! $rocess2 $roduct ins$ection4 and !eneral o$eratin! $rocedures 3hese $rocedures or +or instructions shall be accessible to sho$ "loor $ersonnel

11

3he or!ani5ation shall $ro&ide em$loyee trainin! "or all coatin! o$erations All em$loyees4 includin! bacu$ and tem$orary em$loyees4 shall be trained *ocumented e&idence shall be maintained sho+in! Is mana!ement $ro&idin! the em$loyees trained and the e&idence shall include em$loyee trainin! "or coatin!2 an assessment o" the e""ecti&eness o" the trainin! %ana!ement shall de"ine the quali"ication requirements "or each "unction4 and on!oin! or "ollo+ u$ trainin! shall also be addressed

11<

Is there a res$onsibility matrix to ensure that all ey mana!ement and su$er&isory "unctions are $er"ormed by quali"ied $ersonnel2

3he or!ani5ation shall maintain a res$onsibility matrix identi"yin! all ey mana!ement and su$er&isory "unctions and the quali"ied $ersonnel +ho may $er"orm such "unctions It shall identi"y b oth $rimary and secondary 'bacu$) $ersonnel "or the ey "unctions 'as de"ined by the or!ani5ation) 3his matrix shall be readily a&ailable to mana!ement at all times


*A

Satisfactory

ot Satisfactory





117

118

Qestion

Is there a $re&enti&e maintenance $ro!ram2 Is maintenance data bein! utili5ed to "orm a $redicti&e maintenance $ro!ram2



3he or!ani5ation shall ha&e a documented $re&enti&e maintenance $ro!ram "or ey $rocess equi$ment 'as identi"ied by the or!ani5ation) 3he $ro!ram shall be a closedloo$ $rocess that tracs maintenance e""orts "rom request to com$letion to assessment o" e""ecti&eness #qui$ment o$erators shall ha&e the o$$ortunity to re$ort $roblems4 and $roblems shall also be handled in a closedloo$ manner om$any data4 e!4 do+ntime4 quality re6ects4 "irst timethrou!h ca$ability4 recurrin! maintenance +or orders4 and o$eratorre$orted $roblems4 shall be used to im$ro&e the $re&enti&e maintenance $ro!ram %aintenance data shall be collected and analy5ed as $art o" a $redicti&e maintenance $ro!ram

?as the coater de&elo$ed a 3he coater shall de&elo$ and maintain a critical s$are critical s$are $art list4 and are $arts list and shall ensure the a&ailability o" such $arts the $arts a&ailable to minimi5e to minimi5e $roduction disru$tions $roduction disru$tions2

Section 2 - Floor an' aterial %an'ling /esponsiility

1



*oes the "acility ensure that the data entered in the recei&in! system matches the in"ormation on the customer;s shi$$in! documents2

Is $roduct clearly identi"ied and sta!ed throu!hout the coatin! $rocess2

*ocumented $rocesses and e&idence o" com$liance shall exist4 e!4 sho$ tra&elers4 +or orders4 etc 3he "acility shall ha&e a detailed $rocess in $lace to resol&e recei&in! discre$ancies

Procedures "or $art and container identi"ication hel$ to a&oid incorrect $rocessin! or mixin! o" lots A$$ro$riate location and sta!in! +ithin the "acility also hel$ to ensure that orders are not shi$$ed until all required o$erations are $er"ormed ustomer $roduct shall be clearly identi"ied and sta!ed throu!hout the coatin! $rocess Noncoated4 in$rocess4 and "inished $roduct shall be $ro$erly se!re!ated and identi"ied All material shall be sta!ed in a dedicated and clearly de"ined area

*A

Satisfactory

ot Satisfactory





9

Qestion

Is lot traceability and inte!rity maintained throu!hout all $rocesses2


@ut!oin! lot's) shall be traceable to the incomin! lot's) 3he desci$line o" $recisely identi"yin! lots and linin! all $ertinent in"ormation to them enhances the ability to do root cause analysis and continual im$ro&ement



Are $rocedures adequate to $re&ent mo&ement o" non con"ormin! $roduct into the $roduction system2

3he control o" sus$ect or n oncon"ormin! $roduct is necessary to $re&ent inad&ertent shi$ment or contamination o" other lots Procedures shall be adequate to $re&ent mo&ement o" noncon"ormin! $roduct into the $roduction system Procedures shall exist addressin! $ro$er dis$osition4 $roduct identi"ication and tracin! o" material "lo+ in and out o" hold area Noncon"ormin! hold area shall be clearly desi!nated to maintain se!re!ation o" such material



Is there a system to identi"y tra$ $oints in the entire $rocess to reduce ris o" mixed $arts 'ina$$ro$riate4 un"inished or im$ro$erly coated $arts)2

3he coater shall ha&e documented $rocedures to identi"y and monitor tra$ $oints "or each $rocess/equi$ment %onitorin! o" $otential tra$ $oints shall occur "or e&ery $art chan!eo&er

<

7

Are containers "ree o" ina$$ro$riate material2

Is $art loadin! s$eci"ied4 documented and controlled2

ontainers handlin! customer $roduct shall be "ree o" ina$$ro$riate material A"ter em$tyin! and be"ore re usin! containers4 containers shall be ins$ected to ensure that all $arts and in a$$ro$riate material ha&e been remo&ed 3he source o" ina$$ro$riate material shall be identi"ied and addressed 3his is to ensure that no noncon"ormin! coated $arts or ina$$ ro$riate material contaminate the "inished lot

oadin! $arameters shall be s$eci"ied4 documented and controlled #xam$les include $arts $er rac and load si5e .e"er to Process 3ables "or "requency o" checs


*A

Satisfactory

ot Satisfactory





Qestion


Bn$lanned or emer!ency do+ntime !reatly raises the ris o" im$ro$er $rocessin! @$erators shall be trained in material handlin!4 containment action4 and $roduct se!re!ation in the e&ent o" an equi$ment emer!ency includin! $o+er "ailure 3rainin! shall be documented Cor instructions s$eci"ically addressin! $otential ty$es o" equi$ment emer!encies and "ailures shall be accessible to and understood by equi$ment o$erators 3hese instructions shall address containment/reaction $lans related to all elements o" the $rocess #&idence shall e xist sho+in! dis$osition and traceability o" a""ected $roduct

8

Are o$erators trained in material handlin!4 containment action and $roduct se!re!ation in the e&ent o" an equi$ment emer!ency includin! $o+er "ailure2

>

Is the handlin!4 stora!e and $aca!in! adequate to $reser&e $roduct quality2

3he coater;s loadin!/unloadin! systems4 in$rocess handlin! and shi$$in! $rocess shall be assessed "or ris o" $art dama!e or other quailty concerns

10

Are $lant cleanliness4 houseee$in!4 en&ironmental and +orin! conditions conduci&e to control and im$ro&ed quality2

Plant cleanliness4 houseee$in!4 en&ironmental4 and +orin! conditions shall be conduci&e to controllin! and im$ro&in! quality 3he coater should e&aluate such conditions and their e""ect on quality A houseee$in! $olicy shall be clearly de"ined and executed 3he "acility shall be re&ie+ed "or the "ollo+in! items: loose $arts on "loorD s$illa!e around tansD o&erall $lant li!htin!D "umes etc

11

Are $rocess control $arameters monitored $er "requencies s$eci"ied in Process 3ables2

Process control $arameters shall be monitored $er "requencies s$eci"ied in Process 3ables om$uter monitorin! equi$ment +ith alarms and alarm lo!s satis"y the &eri"ication requirement A desi!nated "loor $erson shall &eri"y the $rocess $arameters4 e!4 by initialin! a stri$ chart or data lo!


*A

Satisfactory

ot Satisfactory





Qestion


1

3here are documented reaction $lans to both out o" Are out o" control/s$eci"ication control and out o" tolerance $rocess $arameters $arameters re&ie+ed and 3here is documented e&idence that reaction $lans are reacted to2 "ollo+ed

19

Are InProcess / Final 3est Frequencies $er"ormed as s$eci"ied in Process 3ables2

1

Is $roduct test equi$ment &eri"ied2

InProcess / Final 3est Frequencies shall be $er"ormed as s$eci"ied in Process 3ables .e"er to Process 3ables

3est equi$ment shall be &eri"ied/calibrated $er a$$licable customer s$eci"ic standard or $er an a$$licable consensus standard4 e!4 A,3%4 ,A#4 I,@4 NI,34 etc Veri"ication/calibration results shall be internally re&ie+ed4 a$$ro&ed and documented .e"er to Process 3ables "or "requency o" checs


*A

Satisfactory

ot Satisfactory



Section 3 - &o A'it - Finishe' Pro'ct /eie.

&o I'entity: Cstomer: Shop ,r'er mer: Part mer: Part "escription: Coating /e0irements:

-uestion E

ob Audit -uestion

.elated ,A -uestion E

91

Is contract re&ie+ and ad&anced quality $lannin!4 F%#A4 control $lans4 etc4 $er"ormed by quali"ied indi&iduals2

11 1 19 1 1<

9

*oes the oater ha&e the $ro$er customer s$eci"ications "or the $art2

1

99

Is a sho$ tra&eler created to meet customer requirements2

1< 1

9

Is material identi"ication '$art numbers4 lot numbers4 contract numbers4 etc) maintained throu!hout the coatin! $rocess2

 9 

9

Is there documented e&idence o" .ecei&in! Ins$ection2

1

9<

Are the oadin! / .acin! requirements identi"ied2

ustomer or Internal .equirement

ob ',ho$) @rder or .e"erence *ocumentation .equirement

N/A

N/A

1< 7 >

Actual ondition '@b6ecti&e #&idence)

Pass / Fail / N/A




-uestion E

97

ob Audit -uestion Is the $ro$er $rocedure or $rocess s$eci"ication used2 .e"er to Process 3ables "or s$eci"ic $arameters ist $arameters that +ere &eri"ied in this audit in the s$aces $ro&ided belo+

.elated ,A -uestion E 1 1< 1 11 19




Pass / Fail / N/A




-uestion E

98 981

98

989

98

ob Audit -uestion Chat are the $roduct ins$ection requirements2 .equirement: oatin! 3hicness 3est %ethod : 3est "requency or quantity: ,election o" sam$les: ,$eci"ication: .equirement: orrosion .esistance 'i" a$$licable) 3est %ethod 's): 3est "requency or quantity: ,election o" sam$les: ,$eci"ication: .equirement: ?ydro!en #mbrittlement .elie" 'i" a$$licable) 3est %ethod : 3est "requency or quantity: ,election o" sam$les: ,$eci"ication: .equirement: Adhesion 3est %ethod 's): 3est "requency or quantity: ,election o" sam$les: ,$eci"ication:

.elated ,A -uestion E 1 19 1




#ach $art may ha&e one or more requirements determined by the coatin! s$eci"ication Parts must meet each requirement ist each requirement belo+ and &alidate 'isted belo+ are some exam$les)

Pass / Fail / N/A




-uestion E 98

98<

ob Audit -uestion .equi rement:  ure 3est %ethod: 3est "requency or quantity: ,election o" sam$les: ,$eci"ication .equirement: 3orque 3ension 'i" a$$licable) 3est %ethod: 3est "requency or quantity: ,election o" sam$les: ,$eci"ication:





Pass / Fail / N/A




-uestion E 987

988

98>

9810

ob Audit -uestion .equirement: A$$earance '*ecorati&e) 3est %ethod: 3est "requency or quantity: ,election o" sam$les: ,$eci"ication .equirement: *imensional 'i" a$$licable) 3est %ethod: 3est "requency or quantity: ,election o" sam$les: ,$eci"ication: .equirement: olor and =loss '*ecorati&e) 3est %ethod: 3est "requency or quantity: ,election o" sam$les: ,$eci"ication: .equirement: ustomer ,$eci"ic 3est %ethod's): 3est "requency or quantity: ,election o" sam$les: ,$eci"ication:





Pass / Fail / N/A




-uestion E



,perator or Inspector /esponsiilities 1 1<  9 11

9>

Cere a$$ro$riate $rocess ste$s si!ned o""2

910

Cere all ins$ection ste$s4 as documented in the control $lan $er"ormed2

911

Cere ste$s/o$erations $er"ormed that +ere not documented in the control $lan2

1 1 1<

91

I" additional ste$s +ere $er"ormed4 +ere they authori5ed2

1 1 1< 110 11<

919

*oes the !o&ernin! s$eci"ication allo+ re$rocessin! or re+or2

1 110

91

I" the order +as certi"ied4 did the certi"ication accurately re"lect the $rocess $er"ormed2

11 19

91

Cas the certi"ication si!ned by an authori5ed indi&idual2

91<

Are the $arts and containers "ree o" ina$$ro$riate ob6ects or contamination2

1 1

11< <




Pass / Fail / N/A




-uestion E



Pac4aging /e0irements 917

918

91> 90

Are $aca!in! requirements identi"ied2 Are $arts $aca!ed to minimi5e mixed $arts '"or exam$le4 $arts $aced o&er hei!ht o" container)2 Shipping /e0irements Cere the $arts $ro$erly identi"ied2 Cere the containers $ro$erly labeled2

< 7 > < 7 > 9 > 9 >




Pass / Fail / N/A


P/,C#SS TA!8# A - Pretreatment (A0eos) All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5

/elate' CSA Qestion 5

Control

onitoring

Per ontrol Plan

Per lot

Pressure/A!itation

Automatic/%anual

Per ontrol Plan/o! ,heet '1/shi"t minimum)

3em$erature

Automatic/%anual

AQ;#,;S C8#AI$ P/,C#SS (Al4aline or Aci')

167 A11

Category*Process Steps

1

3here shall be an incomin! $art assessment $rocedure +ith criteria

267

Cleaning !ath(s)

A1

11

A

1 11 1

A9

1 11

3he "ollo+in! checs shall be $er"ormed durin! $roduction:

Per ontrol Plan/o! ,heet


P/,C#SS TA!8# A - Pretreatment (A0eos) All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5



367

Control

onitoring

/inse !ath(s) 3he "ollo+in! checs shall be $er"ormed durin! $roduction:

A91

11

A9

1 11 1

Pressure/A!itation

Automatic/%anual


A99

1 11 1

3em$erature

Automatic/%anual


A9

1 1< 11 1

3ime

Automatic/%anual


1


P/,C#SS TA!8# ! - Pretreatment (echanical) All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5


167


Control

onitoring

Per ontrol Plan

Per lot

Abrasi&e media "lo+

Automatic/%anual


No55le air $ressure

Automatic/%anual


A!/ASI<# !8AST P/,C#SS

G11

1


G1

11


G19

1 1< 11 1

G1

1 1< 11


P/,C#SS TA!8# C - Pretreatment (Phosphating)

All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item E



167


1

267 11 1

37

Per lot

Automatic/%anual


Automatic/%anual


1

Automatic/%anual


%anual

Per hemical %anu"acturer;s =uideline


11 Pressure/A!itation 1 1 1< 11 1

9



Per ontrol Plan

/inse Con'itioner (If Applicale)

1



onitoring

Conersion Coating

11



Control

3ime

11 hemical oncentration 1 11

3here is a dum$ schedule "or rinse conditioner Conersion Coating !ath


P/,C#SS TA!8# C - Pretreatment (Phosphating)

All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item E



=67

9

onitoring

%anual


Automatic/%anual


Automatic/%anual


%anual

Per hemical %anu"acturer;s =uideline

/inse After Phosphate

1



Control

11


1

11 Im$urity oncentration 'e! 3itration4 1 onducti&ity)

1

11 Pressure/A!itation 1



1 1< 11 1



11

3ime

3here is a dum$ schedule "or rinses


P/,C#SS TA!8# " - Po.'er All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5


167 *11


Control

onitoring

%anual

Per ontrol Plan/o! ,heet '1 $er hour)

Automatic/%anual


Automatic


3he !round is checed usin! a 00 &olt me!ohm meter 'less than 1me!ohm resistance)

Automatic/%anual


3he air dryer and "ilter are on main com$ressed air line

Automatic/%anual


Po.'er Paint Application 1 11

267

Parts are checed exitin! dryo"" o&en "or cleanliness and tra$$ed +ater4 $rior to enterin! $o+der booth Po.'er !ooth an' #0ipment

*1

1 11 1

*

1 1< 117 11 1

*9

1 11 1

*

1 117 11 1 1 117

3he tem$erature o" $arts enterin! the coatin! booth is monitored

3he con&eyor is o$eratin! at the $ro$er line s$eed 'no abru$t mo&ement or contact bet+een $arts)

Per ontrol Plan/o!


P/,C#SS TA!8# " - Po.'er All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5


*1

1 117 11 1

Control

onitoring

All !uns are o$erational and in !ood re$air

%anual


*19

1 117 11 1

3he &enturis in the "eed $um$s and the $ic u$ tubes in the ho$$er are checed

%anual

Per P% schedule

*1

1 11 1

3he "eed hoses are checed to ensure that they ha&e no excessi&e bends and ins

%anual

Per ontrol Plan/o! ,heet '1/day minimum)

3he &ir!in/reclaim ratio is checed '"eed $ressure)

%anual

* 1

1 11


Per ontrol Plan/o!


P/,C#SS TA!8# # - #lectrocoat All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5


167 #11


Control

onitoring

%anual


Pre-#lectrocoat Paint Application Part Appearance 1 11

267

Incomin! $arts are ins$ected "or cleanliness and/or uni"orm $hos$hate coatin! '+hen $hos$hate is used) #lectrocoat 8aoratory

#1

1

aboratory equi$ment is calibrated and in !ood +orin! order

N/A

#

1

aboratory standards and rea!ents are $ro$erly stored4 labeled4 and not ex$ired

N/A

#9

1

aboratory records4 internal and external4 are "iled and accessible "or re&ie+

N/A


Gath $arameters '$?4 cond ucti&ity4 solid content4 tem$erature4 &olta!e) are checed and ad6usted

Automatic/%anual


ine s$eed setu$ is checed

Automatic/%anual


%anual

@nce/+ee minimum

Automatic/%anual


367

#lectrocoat Tan4

#91

1 11 1

#9

1 1< 11 1

#99

1 11 1

ine s$eed is &eri"ied

#9

1 11 1

3here is circulation and it is monitored '"lo+ meter4 $ressure !a!e)

1


P/,C#SS TA!8# # - #lectrocoat All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5


=67


Control

onitoring

Anolyte System

#1

1 11 1

3he anolyte solution is bein! controlled +ithin the required conducti&ity limits

Automatic/%anual


#

1 11 1

3he conducti&ity readin! on the anolyte tan has been con"irmed in the laboratory

Automatic/%anual

Per ontrol Plan/o! ,heet 1 / +ee

#9

1 11 1

3he $? o" the anolyte solution has been checed

Automatic/%anual

Per ontrol Plan/o! ,heet '1 $er shi"t)

#

1 11 1

Anodes ha&e been ins$ected

%anual

Per ontrol Plan/o! ,heet '1 $er six months)

#

1 11 1

3he anolyte solution is bein! circulated to each cell

Automatic/%anual


#<

1 11 1

*um$ and clean schedule "or anolyte bein! maintained

%anual


#7

1 11 1

Am$era!e dra+ has been checed on each anode

Automatic/%anual


3he $ro$er &olta!e is bein! used "or the load si5e

%anual

$er #qui$ %"!

3he ram$ u$ time to "ull &olta!e has been &eri"ied

Automatic/%anual

Per ontrol Plan/o! ,heet '1 $er shi"t)

>67

#1

#

/ectifier 1 1< 11 1 1 11


P/,C#SS TA!8# F - Spray All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5


167 F11 F1


Control

onitoring

%anual


Part Appearance 1 11 11

Incomin! $arts are ins$ected "or cleanliness4 tra$$ed +ater or +ater s$ots as +ell as uni"orm $hos$hate coatin! '+hen $hos$hate is used) Ins$ection criteria are $osted

CQI-12 Special Process: Coating System Assessmen Version 14 Issued 8/07

P/,C#SS TA!8# F - Spray All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen perfo rming the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5


267


Control

onitoring

Automatic/%anual

Per Paint %anu"acturer .ecommendation

Paint iing

F1

1 11 1

Paint mixin! rooms are controlled 'mixin! tan !roundin!4 closed container4 $ro$erly enclosed s$ace4 tem$erature4 clean en&ironment)

F

1 11 1

FIF@ system is bein! utili5ed

%anual


F9

1 1< 117 11 1

Paint a!itation/time and reduction 'sol&ent $aca!e) a re $ro$er and documented

%anual


Viscosity and tem$erature are in o$erational limits and documented

%anual

Per ontrol Plan/o! ,heet/Paint %anu"acturer .ecommendation

F

1 1< 117 11



Item 5


Sstrate Con'itioning (Flame9 Plasma9 etc) applicale)

367 F91


1 11

Control (If

Incomin! $arts are ins$ected to ensure that they are "ree o" dirt and contamination

%anual

1 F9

117

onitoring

11 Flame/Plasma is set at o$erational limits $er equi$ment and material su$$lier recommendations

Automatic

Per control $lan and equi$ment and substrate su$$liers recommendations

%anual

Per ontrol Plan

%anual


1 1 F99

11 19

=67 F1

F 

Final sur"ace tension is +ithin s$eci"ications Primer*Promoter

1 11 1 117

Incomin! $arts are ins$ected to ensure that they are "ree o" dirt and contamination *estatici5in! air is o$erational 'Plastic $arts only)

Automatic




Item 5


>67 F1


Control

onitoring

%anual

Per ontrol Plan / material su$$lier 'once $er shi"t minimum)

Flashtimes bet+een coats are set at su$$liers recommended times

Automatic/%anual

Per ontrol Plan/material su$$lier

Gooth tem$erature and humidity are monitored or set +ithin o$erational limits i" controlled '.equired "or +aterborne coatin!s)

Automatic/%anual


Atomi5er $arameters '"luid "lo+4 air $ressures 'atomi5in! "an4 sha$in!)4 electrostatics and mixin!) are set +ithin o$erational limits

Automatic/%anual

Per ontrol Plan/o! ,heet '1 $er month minimum)

!asecoat (If applicale) 1 11


1 F

F9

F

1< 11 19 1 1< 117 11 1 1 1< 117 11

CQI-12 Special Process: Coating System Assessmen Version 14 Issued 8/07


Item 5


@67 F71


Control

onitoring

%anual

Per ontrol Plan / material su$$lier 'once $er shi"t minimum)

Flashtimes bet+een coats are set at su$$liers recommende d times

Automatic/%anual

Per ontrol Plan/material su$$lier

Gooth tem$erature and humidity are mon itored or set +ithin o$erational limits i" controlled '.equired "or +aterborne coatin!s)

Automatic/%anual


Atomi5er $arameters '"luid "lo+4 air $ressures 'atomi5in! "an4 sha$in!)4 electrostatics and mixin!) are set +ithin o$erational limits

Automatic/%anual

Per ontrol Plan/o! ,heet '1 $er month minimum)

Clearcoat 1 11


1 F7

F79

F7

1< 11 19 1 1< 117 11 1 1 1< 117 11


P/,C#SS TA!8# $ - "ip*Spin All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5


167 =11

=1

=19


Control

onitoring

%anual

Per ontrol Plan/o! ,heet 'each lot)

Automatic/%anual


%anual


Coating aterial Application 1 11 1 11 < 117

267

A"ter $retreatment4 $arts are ins$ected "or "lash rust4 +etness4 oil or other de"ects I" $hos$hated4 $arts are checed "or uni"ormity o" $hos$hate coatin! ,ids/bins used to hold $arts bet+een coatin! o$erations are "ree o" oil4 !rease or other contaminants Coating !ath

1



Item 5



Control

onitoring

The follo.ing chec4s shall e performe' 'ring pro'ction:

=8

=>

1 11 1

Paint 3em$erature

%anual


=10

1 11 1

Viscosity

%anual


=11

1 11 1

 ,olids 'by +ei!ht)

%anual

Per ontrol Plan/o! ,heet '1/*ay minimum)

1




Item 5


367


Control

onitoring

Automatic/%anual


Application Parameters A system is in $lace to ensure $ro$er baset +ei!hts "or s$eci"ic $arts4 such as $rocessin! manual4 tra&eller4 or $rocess reci$e

=91

1 1<

=9

1 1<

Gasets are e$t less than /9 "ull

Automatic/%anual


=99

1 1<

*i$ time is controlled

Automatic/%anual




Item 5

=9>

=910

/elate' CSA Qestion 5 1 1< 1 1<


Control

onitoring

3umble time is in/out o" coatin! controlled 'i" a$$licable)

Automatic/%anual


3here is an adequate system to ee$ $arts le&el !oin! into the o&en 'rain!4 &ibe table4 etc)

Automatic/%anual



P/,C#SS TA!8# % - Atophoretic All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5



167

91

Coating !ath

?11

1 11 1

Control

onitoring

%ixer s$eed and direction are monitored and ad6usted

Automatic/%anual


?1

1 1< 11 1

3ime 'hoist $ro!ram) is &eri"ied

Automatic/%anual

Per ontrol Plan/o! ,heet '1/day minimum)

?19

1 117 11 1

on&eyor s$eed is &eri"ied 'i" a$$licable)

%anual

?1

1 1< 11 1

3em$erature is monitored and controlled

Automatic

1

Annually or a"ter re$air



P/,C#SS TA!8# % - Atophoretic All re0irements gien elo. are sor'inate to cstomer specific r e0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item 5



367

9

/eaction /inse

?91

?9

1 11 1 1 11

Control

onitoring

hemical concentration 'titration4 conducti&ity4 $?4 ?ach %eter 3est) is checed and maintained

Automatic/%anual


Pum$ $ressure or a!itator s$eed is monitored

Automatic/%anual



P/,C#SS TA!8# I - Conectie Cre All re0irements gien elo. are sor'inate to cstomer specific re0irements6 The cstomer may hae a''itional re0irements9 e6g69 inspection testing9 greater fre0encies9 etc6 hen performing the o a'it9 the a'itor shall erify coater is conforming to cstomer re0irements6

Item E



Control

onitoring

Automatic

1/shi"t minimum or at e&ery material chan!e Per coatin! su$$lier recommendation

%anual

1/month minimum

167 I11

1 1< 11 1

@&en tem$erature set $oint and limits are checed and documented

I1

117

Part tem$erature $ro"ile is monitored

I19

1 1< 11 1

Pro$er cure time is maintained 'i" a$$licable)

Automatic/%anual

Per coatin! su$$lier recommendation

I1

1 1< 117 11 1

on&eyor s$eed is maintained 'i" a$$licable)

Automatic

1/month minimum 'a"ter P%)

I1

1 11 1

Automatic/%anual

Per coatin! su$$lier recommendation

Air"lo+ is measured 'i" required by coatin! su$$lier)

Coating System Assessment CQI-12

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