CQI-9热处理评估标准[英文]

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1、For Ford Internal Use Only CQI-9 Special Process: Heat Treat System Assessment For Ford Internal Use Only For Ford Internal Use OnlyAIAG PUBLICATIONS An AIAG publication reflects a consensus of those substantially concerned with its scope and provisions. An AIAG publication is intended as a guide to

2、 aid the manufacturer, the consumer and the general public. The existence of an AIAG publication does not in any respect preclude anyone from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the publication. CAUTIONARY NOTICE AIAG publications are s

3、ubject to periodic review and users are cautioned to obtain the latest editions. MAINTENANCE PROCEDURE Recognizing that this AIAG publication may not cover all circumstances, AIAG has established a maintenance procedure. Please refer to the Maintenance Request Form at the back of this document to su

4、bmit a request. APPROVAL STATUS The AIAG Quality Steering Committee and designated stakeholders approved this document for publication in March 2006. Published by: Automotive Industry Action Group 26200 Lahser Road, Suite 200 Southfield, Michigan 48034 Phone: (248) 358-3570 Fax: (248) 358-3253 AIAG

5、Copyright and Trademark Notice: The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. 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 persons of

6、ficial duties. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of fe

7、deral law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group. 2006 Automotive Industry Action Group Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Da

8、ted: N/A 1For Ford Internal Use OnlyFOREWORD Automotive Industry Action Group (AIAG) committees 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 is to prepare A

9、utomotive Standards and System Requirements. Draft documents adopted by the technical committees are circulated to the Steering Committee for review and consensus approval. Publication of the documents requires approval by the Quality Steering Committee. The Quality Steering Committee would like to

10、acknowledge and thank the following individuals and their companies who have contributed time and effort to the development of this document. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 2For Ford Internal Use Only ACKNOWLEDGEMENTS Core Memb

11、ers: Pete Batche Textron Fastening Systems Co. Mel Dilley DaimlerChrysler Corp. Curt Holmes Metaldyne Ed Jamieson Bodycote Thermal Processing Young Kim Ford Motor Company Brett Lenhausen General Motors Corporation Philip Mikula TRW, Inc. Murli Prasad General Motors Corporation Supporting Members: To

12、dd Bensinger DaimlerChrysler Corp. Scott Brodersen DaimlerChrysler Corp Dave Calkins DaimlerChrysler Corp Leonard Gadzinski Textron Fastening Systems Co. Tim Green BSI Americas, Inc. Dave Hernacki Commercial Steel Treating, Corp. Dean Higdon Textron Fastening Systems Co. Medina Kaknjo Ford Motor Com

13、pany Jeff Martin ZF Friedrichshafen, AG Mike Oberg Induction Services, Inc. Mike Wiezbowski DaimlerChrysler Corp Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 3For Ford Internal Use OnlyTABLE OF CONTENTS AIAG PUBLICATIONS.1 CAUTIONARY NOTICE.

14、1 MAINTENANCE PROCEDURE.1 APPROVAL STATUS.1 FOREWORD.2 ACKNOWLEDGEMENTS.3 1.0 INTRODUCTION.5 1.1 GENERAL.5 1.2 PROCESS APPROACH.5 1.3 HEAT TREAT SYSTEM ASSESSMENT GOALS.5 1.4 ASSESSMENT PROCESS.5 1.5 ASSESSOR QUALIFICATIONS.6 1.6 OTHER REQUIREMENTS.6 2.0 SCOPE.7 2.1 GENERAL.7 2.2 APPLICATION.7 3.0 T

15、HE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE.94.0 SPECIAL PROCESS: HEAT TREAT ASSESSMENT FORMS.10 APPENDIX A PROCESS TABLES .39 APPENDIX B GLOSSARY.56 ABOUT AIAG .60MAINTENANCE REQUEST .61 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 4For Ford

16、Internal Use Only 1.0 INTRODUCTION 1.1 General The work of preparing CQI 9: Special Process: Heat Treat System Assessment (HTSA) was carried out through the AIAG Heat Treat Work Group. These heat treat requirements are complementary to customer and product standards. The HTSA can be used to assess a

17、n organizations ability to meet the requirements in this assessment, as well as customer, regulatory, and the organizations own requirements. The HTSA can also be used between an organization and its suppliers. In the HTSA, the word “shall” indicates a requirement. Where the term “such as” is used,

18、any suggestions given are for guidance only. 1.2 Process Approach The HTSA supports the automotive process approach as described in ISO/TS16949:2002. 1.3 Heat Treat System Assessment Goals The goal of the HTSA is the development of a heat treat management system that provides for continual improveme

19、nt, emphasizing defect prevention and the reduction of variation and waste in the supply chain. The HTSA, coupled with an internationally recognized quality management system and applicable customer-specific requirements, defines the fundamental requirements for heat treat management systems. The HT

20、SA is intended to provide a common approach to a heat treat management system for automotive production and service part organizations. 1.4 Assessment Process Ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to re-examine the continuing compliance with the

21、 HTSA. Each assessment shall include a review of the organizations systems using the HTSA. Successive Job Audits (Section 4.0 of this document) shall sample parts from different automotive component manufacturers that require compliance to the HTSA document. The assessment shall use the process appr

22、oach to auditing as identified by the requirements of ISO/TS 16949:2002. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 5For Ford Internal Use Only1.5 Assessor Qualifications Assessors shall have the following specific experience to conduct th

23、e HEAT TREAT SYSTEM ASSESSMENT portion of the assessment: Be an experienced quality management system (QMS) internal auditor (e.g., ISO 9000:2000, ISO/TS 16949:2002) 1.6 Other Requirements The organization shall keep records as evidence of compliance to the requirements identified in the HTSA, as we

24、ll 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. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Da

25、ted: N/A 6For Ford Internal Use Only 2.0 SCOPE 2.1 General This document specifies process requirements for an organization or its suppliers performing applicable heat treating, who need to demonstrate ability to consistently provide product that meets customer and applicable regulatory requirements

26、, and enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system. The Heat Treat System Assessment is applicable to sites where customer-specified parts for production and/or service are processed throughout the automoti

27、ve supply chain. 2.2 Application All requirements of the HTSA are generic and are intended to be applicable to all organizations performing the heat treat operations addressed in this document, regardless of type, size, and product. Four Process Tables have been developed and the appropriate table(s

28、) is to be referenced during the assessment. The Process Tables are specific to heat treat processes as noted below: Process Table 1 Ferrous Carburizing Carbonitriding Carbon Restoration or Correction Neutral Hardening (Quench and Temper) Austempering Martempering Tempering Precipitation Hardening A

29、ging Process Table 2 Ferrous Nitriding (Gas) Ferritic Nitrocarburizing (Gas or Salt) Process Table 3 Aluminum Heat Treating Process Table 4 Induction Heat Treating (Ferrous) Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 7For Ford Internal Use

30、 Only These Process Tables contain requirements for: 1. Process and Test Equipment 2. Pyrometry 3. Process Monitor Frequencies 4. In-Process/Final Test Frequencies 5. Quenchant and Solution Test Frequencies The Process Tables specify the tolerances of process parameters and the frequencies for check

31、ing process control parameters and parts. The Requirements/Guidelines in the HTSA form will notify the assessor when to refer to the Process Tables. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 8For Ford Internal Use Only 3.0 THE HEAT TREAT

32、SYSTEM ASSESSMENT PROCEDURE 1. Obtain current copy of CQI-9 Special Process: Heat Treat System Assessment Guideline from AIAG. 2. Identify all heat treat processes to which CQI-9 Special Process: Heat Treat System Assessment Guideline applies (see CQI-9, 2.2). Record these processes on the HTSA. 3.

33、Complete the HTSA, determining the level of compliance. Sections 1-3 shall be completed first and independent of any job audits performed. A minimum of one job audit (Section 4) shall be performed during each assessment. 4. Address each “unsatisfactory” item and determine corrective action, includin

34、g root cause analysis and implementation of the corresponding corrective action(s). Records of corrective action, including verification, shall be maintained. 5. Assessments shall be conducted annually unless otherwise specified by the customer. Special Process: Heat Treat System Assessment CQI-9 Is

35、sue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 9For Ford Internal Use Only 4.0 SPECIAL PROCESS: HEAT TREAT ASSESSMENT Cover Sheet11 Section 1-314 Section 1: Management Responsibility & Quality Planning15 Section 2: Floor and Material Handling Responsibility22Section 3: Equipment27Section 4: Job A

36、udit33 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 10For Ford Internal Use Only Instructions for completing the Cover Sheet 1. Facility Name: Name of the facility being assessed. One form shall be used for each facility. The facility may ha

37、ve several buildings or physical locations in the same general area. If there is a separate management team (Quality Manager and Metallurgist) or different management system, then these locations shall be considered as separate facilities. 2. Address: The street address of the facility being assesse

38、d; P.O Box numbers may be given as additional information. 3. Phone Number: The phone number of the facility. If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used. 4. Fax Number: The fax number of the facility. 5. Number of

39、Heat Treat Employees at this Facility: The number of employees, salaried and hourly, associated with the heat treat operation at this facility. 6. Captive Heat Treater (Y/N): Enter “Y” if this facility heat treats components for their own company. Enter “N” if the company does not heat treat any com

40、ponents for their own company. 7. Commercial Heat Treater (Y/N): Enter “Y” if this facility heat treats components for companies other than their own company. Enter “N” if this facility does not heat treat any components for other companies. 8. Date of Assessment: Enter the date(s) of the assessment

41、. An alphanumeric format shall be used to avoid confusion with different numeric formats. Example: May 3 4, 2006 9. Date of Previous Assessment: List the date of the previous CQI-9 Special Process: Heat Treat System Assessment of this facility. 10. Type(s) of Thermal Processing at this Facility: Pla

42、ce a checkmark to designate all thermal 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 Heat Treat System Assessment. 11. Current Quality Certificat

43、ion(s): The heat treater shall list their current quality certifications, e.g., ISO/TS 16949:2002, ISO 9000:2002. 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 al

44、so be given. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 11For Ford Internal Use Only 12. Date of Re-assessment (if necessary): If “Not Satisfactory” findings were observed from the original assessment, then the heat treater shall address e

45、ach 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 4, in the original assessment, shall be modified to reflect that the e

46、vidence, relating to the implementation of the corrective action(s), has been observed. Also, the “Number of Not Satisfactory Findings” shall be modified as appropriate. 13. Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available, of the principal partic

47、ipants from the heat treaters organization. 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 assessme

48、nt. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 12For Ford Internal Use OnlySpecial Process: Heat Treat Process Assessment Facility Name:AddressPhone NumberType(s) of Thermal Processing at this Location:Fax NumberProcess Table 1CarburizingN

49、umber of Heat Treat Employees at this Location:CarbonitridingCarbon CorrectionCaptive Heat Treater (Y/N)Neutral HardeningCommercial Heat Treater (Y/N)Austempering / MartemperingTemperingDate of Evaluation:Precipitation Hardening / AgingDate of Previous Evaluation:Process Table 2Nitriding (Gas)Ferrit

50、ic-Nitrocarburizing (Gas or Salt)Process Table 3Aluminum Heat TreatmentProcess Table 4Induction Heat TreatingCurrent Quality Certification(s)Date of Re-evaluation (if necessary):Personnel Contacted:NameTitlePhoneEmailAuditors/AssesorsNameCompanyPhoneEmailNumber of Not Satisfactory FindingsSpecial Pr

51、ocess: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 13For Ford Internal Use Only Instructions for completing Sections 1 3 Sections 1 - 3 contain questions and the requirements/guidance for each question. The Sections are: Section 1 Management Responsibility

52、& Quality Planning Section 2 Floor and Material Handling Responsibility Section 3 Equipment The assessor shall assess the heat treaters compliance to Sections 1 3 by comparing the evidence presented by the heat treater to the requirements listed in the “Requirements/Guidance” column. NOTE 1: In the

53、“Requirements/Guidance” column, the word “shall” indicates a requirement and the term “such as” indicates that any suggestions given are for guidance only. NOTE 2: The “Requirements/Guidance” column will indicate to the assessor when the Process Tables are pertinent to the Questions. When the Proces

54、s Tables are pertinent to the Question, the assessor shall assess the heat treaters compliance to the specified section(s) in the Process Tables. NOTE 3: If the question is not applicable to the heat treater, then the assessor shall place a checkmark in the “N/A” Assessment column. If the observed e

55、vidence 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 “Objective Evid

56、ence” column and place a check mark in the “Not Satisfactory” column. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 14For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNee

57、ds Immediate Action1.1Is there a dedicated and qualified heat treat person on-site?To ensure readily available expertise, there shall be a dedicated and qualified heat treat person on site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A

58、 job description shall exist identifying the qualifications for the position including metallurgical and heat treat knowledge. The qualifications shall include a minimum of 5 years experience in heat treat operations or a combination of a minimum of 5 years of formal metallurgical education and heat

59、 treat experience.1.2Does the heat treater perform APQP?The organization shall incorporate a documented Advance Product and Quality Planning (APQP) procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort

60、 as defined by the organization. After the Production Part Approval Process (PPAP) is approved by the customer, no process changes are allowed unless approved by the customer. The heat treater shall contact the customer when clarification of process changes is required. This clarification of signifi

61、cant processes change shall be documented.1.3Are heat treat PFMEAs up to date and reflecting current processing?The organization shall incorporate the use of a documented Process Failure Mode and Effects Analysis (PFMEA) procedure and ensure the PFMEAs are updated to reflect current part quality sta

62、tus.The PFMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key heat treat process parameters as defined by the organization. A cross-functional

63、team, including a production operator, shall be used in the development of the PFMEA, and items with the highest Risk Priority Numbers (RPNs) shall be addressed annually. All significant or critical characteristics, as defined by the organization and its customers, shall be identified, defined, and

64、addressed in the PFMEA.AssessmentSpecial Process: Heat Treat Process AssessmentSection 1 - Management Responsibility & Quality PlanningSpecial Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 15For Ford Internal Use OnlyQuestion NumberQuestionRequiremen

65、ts / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment1.4Are heat treat process control plans up to date and reflecting current processing?The organization shall incorporate the use of a documented Control Plan pro

66、cedure and ensure the Control Plans are updated to reflect current controls.The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify

67、all equipment used and all key heat treat process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travel

68、ers, and PFMEAs. All significant or critical characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluationof process and product characteristics shall also beaddressed consistent with t

69、he minimum requirements listed in the Process Tables, Sections 3.0 and 4.0. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 16For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot Satisfact

70、oryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment1.5Are all heat treat related and referenced specifications current and available? For Example: SAE; AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. To ensure all customer requirements are both understood and sat

71、isfied, the organization shall have all related heat treat and customer referencedstandards 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, Gen

72、eral Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all relevant customer and industry engineering standards and specifications. This process shall be executed as soon as possible and shall not exceed two week

73、s. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor

74、within the two-week period. The organization shall identify who is responsible for performing these tasks.1.6Is there a written process specification for all active processes? The heat treater shall have written process specifications for all active processes and identify all steps of the process in

75、cluding relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, atmosphere or gas flow settings, belt speeds, quench agitation speeds, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the

76、 organization in order to maintain process control. All active processes should have a written process specification. These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.Special Process: Heat Treat System Assessment CQI-9

77、Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 17For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment1.7Has a valid capability study been performed

78、initially and after process equipment has been relocated, or had a major rebuild?To demonstrate each process is capable of yielding acceptable product the organization shall perform product capability study for the initial validation of each process, after relocation of any process equipment, & afte

79、r a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all heat treat processes per furnace line defined in scope of work & annually thereafter. A furnace line may include a combination of equipmen

80、t that is integrated in the performance of a heat treatment process, i.e. hardening, quenching, and tempering. Capability study techniques shall be appropriate forthe heat treat product characteristics, i.e. tensile strength, case depth, hardness. Any specific customer requirements shall be met, in

81、the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to followed in case capability indices fall outside customer requirements or established ranges.1.8Does the heat treater collect and an

82、alyze data over time, and react to this data? The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time.Methods of analysis shall include ongoing

83、 trend or historical data analysis of significant product or process parameters. The organization shall determine which significant parameters to include in such analysis. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 18For Ford Internal Use

84、OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment1.9Is management reviewing the heat treat monitoring system every 24 hours?Management shall review the furnace monitoring s

85、ystems at intervals not to exceed 24 hours. The heat treat monitoring system includes but is not limited to temperature strip charts, atmosphere strip charts, computer data logs, furnace and operator logs, etc.The management review shall include efforts to detect out-of-control conditions or alarm c

86、onditions.The process of reviewing the furnace data shall be documented and this requirement also applies to computerized data.1.10Are internal assessments being completed on an annual basis, at a minimum, using AIAG HTSA? The organization shall conduct internal assessments on an annual basis, at a

87、minimum, using the AIAG HTSA. Concerns shall be addressed in a timely manner.1.11Is there a system in place to authorize reprocessing and is it documented? The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual.

88、The reprocessing procedure shall describe product characteristics for which reprocessing is allowed aswell as those characteristics for which reprocessing is not permissible.Any reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the ne

89、cessary heat treat modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.1.12Does the Quality Department review, address, and document customer and internal concerns? The qual

90、ity management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces:

91、 N/A, Dated: N/A 19For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment1.13Is there a continual improvement plan applicable to each process defined in th

92、e scope of the assessment?The heat treater shall define a process for continual improvement for each heat treat process identified in the scope of the HTSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and sha

93、ll include timing (estimated completion dates). The organization shall show evidence of program effectiveness.1.14Does the Quality Manager or designee authorize the disposition of material from quarantine status? The Quality Manager is responsible for authorizing and documenting appropriate personne

94、l to disposition quarantine material.1.15Is there an operations manual available to heat treat personnel covering the entire heat treating process?An operations manual shall be available to heat treat personnel covering the entire heat treating process. The manual shall include procedures or work in

95、structions addressing potential emergencies(such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall cover all steps of the operation from product receipt to produ

96、ct shipment and shall be accessibleto shop floor personnel.1.16Is management providing employee training for heat treating?The organization shall provide employee training for all heat treating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence

97、 shall be maintained showing the employees trained and an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed. Special Process: Heat Treat System Assessment CQI-9 Issue: 1

98、.00, Dated 3/2006 Replaces: N/A, Dated: N/A 20For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment1.17Is there a responsibility matrix to ensure that all

99、 key management and supervisory functions are performed by qualified personnel?The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (ba

100、ckup) personnel forthe key functions (as defined by the organization). This matrix shall be readily available to management at all times.1.18Is there a preventive maintenance program? Is maintenance data being utilized to form a predictive maintenance program? The organization shall have a documente

101、d preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and

102、 problems shall also be handled in a closed-loop manner.Company data, e.g., downtime, quality rejects, first-time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Furnaces and generators shall be sched

103、uled for burn-out at frequencies determined by the organization (see Section 1 of the Process Tables).Maintenance data shall be collected and analyzed as part of a predictive maintenance program.1.19Has the Heat Treater developed a critical spare part list and are the parts available to minimize pro

104、duction disruptions?The heat treater shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 21For Ford Internal U

105、se OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment2.1Does the facility ensure that the data entered in the receiving system matches the information on the customers shipp

106、ing documents?It is critical that all customer requirements and lot identification be adequately transferred to internal heat treat documents. The facility shall ensure that the data entered in the receiving system match the information on the customers shipping documents. Documented processes and e

107、vidence of compliance shall exist, e.g., shop travelers, work orders, etc. Sometimes the material received does not precisely correspond to customer shipping documents. The facility shall have a detailed process in place to resolve receiving discrepancies.The requirements stated above also apply to

108、captive heat treat departments. This process refers to receiving and shipping the parts in and out of the heat treat department.2.2Is product clearly identified and staged throughout the heat treat process?Procedures for part and container identification help to avoid incorrect processing or mixing

109、of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the heat treat process. Green, in-process, and finished product shall be prope

110、rly segregated and identified. All material shall be staged in a dedicated and clearly defined area.2.3Is lot traceability and integrity maintained throughout all processes?Out-going lot(s) shall be traceable to the incoming lot(s).The discipline of precisely identifying lots and linking all pertine

111、nt information to them enhances the ability to do root cause analysis and continual improvement.Section 2 - Floor and Material Handling Responsibility Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 22For Ford Internal Use OnlyQuestion NumberQu

112、estionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment2.4Are procedures adequate to prevent movement of non-conforming product into the production system? The control of suspect or non-conforming pr

113、oduct is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification, and tracking of material flow in and

114、 out of the hold area. A non-conforming/hold area shall be clearly designated to maintain segregation of such material.2.5Is there a system to identify trap points in the entire heat treat process to reduce risk of mixed parts (foreign, green, or improperly heat treated parts)?Heat-treating furnaces

115、 and other processing equipment contain areas that have a risk of trapping or holding parts. Such trapping of parts can lead to damage, improperly processed parts or lot mixing/contamination. A system shall exist to identify trap points in the entire heat treat process to reduce risk of mixed parts

116、(foreign, green, or improperly heat treated parts). The heat treater shall have documented procedures to identify and monitor trap points for each process/equipment. Monitoring of potential trap points shall occur for every part changeover.2.6Are containers free of foreign material?Containers handli

117、ng customer product shall be free of foreign material. Containers shall be inspected for foreign material and the source of the foreign material shall be notified. After emptying and before re-using containers, containers shall be inspected to ensure that all parts have been removed. This is to ensu

118、re that no green (un-heat treated) parts contaminate the finished lot.2.7Is furnace loading specified, documented and controlled?Furnace loading parameters shall be specified, documented, and controlled. Examples include feed rate, belt speed, number of parts per fixture, and load weight. Refer to P

119、rocess Tables, Section 3.0, for frequency of checks.Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 23For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate Actio

120、nAssessmentSpecial Process: Heat Treat Process Assessment2.8Are operators trained in material handling, containment action and product segregation in the event of an equipment emergency including power failure? Unplanned or emergency downtime greatly raises the risk of improper processing. Operators

121、 shall betrained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and

122、understood by equipment operators. These instructions shall address containment actions related to all elements of the heat-treating process, e.g., loading, austenitizing, quenching, tempering.2.9Is the handling, storage and packaging adequate to preserve product quality? Some equipment includes con

123、veyors and other moving components that may not be able to handleall part configurations. Other practices such as stacking of overloaded containers can also increase the risk of part damage. Handling, storage, and packaging shall be adequate to preserve product quality. The heat treaters furnace loa

124、ding system, in-process handling, and shipping process shall be assessed for risk of part damage or other quality concerns.2.10Are plant cleanliness, housekeeping, environmental, and working conditions conducive to quality improvements?Plant cleanliness, housekeeping, environmental, and working cond

125、itions shall be conducive to quality improvements. The heat treater should evaluate such conditions and their effect on quality.A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for conditions that are detrimental to quality processing such as loose parts on

126、 floor, oil around quench tanks, inadequate plant lighting, smoke, etc. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 24For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryN

127、eeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment2.11Are parts free from contaminants that would be detrimental to the heat treatment of the product? Many heat-treated parts are subjected to surface finish or appearance operations such as plating or coating after heat tre

128、atment. Parts shall be free from contaminants that are detrimental to subsequent processes or the product. Pre-wash (if applicable) and post-wash parameters shall be monitored and documented. Oils and other contaminants or residues can be difficult to remove once subjected to the heat treatment proc

129、ess. Review the chemical suppliers recommendation for cleaning the system. Parts shall be free of rust, burrs, chips, detrimental amounts of drawing compound, cutting fluids, rust preventing oils, lubricants, etc., prior to heat treat. Note: Refer to the appropriate heat treaters requirements and sp

130、ecifications to determine acceptability. Refer to Process Table, Section 5.0, for frequency of checking washer solutions. 2.12Is the quenching system monitored, documented, and controlled?The quenching system shall be monitored, documented, and controlled. The temperature, agitation, level, concentr

131、ation (if applicable), time inthe quenchant, and additions shall be controlled to the heat treaters specifications. Refer to Process Tables, Sections 3.0 and 5.0, for frequency of checks. Computer-monitoring equipment, with alarms and alarm logs, satisfy the verification requirement. Quench delay to

132、lerance and alarm is required for furnaces with integral quench tanks. Temper delay time shall be specified by the heat treater for parts that are quenched and tempered, e.g., carburizing, carbonitriding, neutral hardening, solution treating and aging.Special Process: Heat Treat System Assessment CQ

133、I-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 25For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment2.13Is soluble oil or other rust preventive

134、 monitored and controlled if applicable?Parts are often dipped in or sprayed with rust preventive solutions immediately after the heat treating process. Soluble oil solutions or other rust preventive solutions shall be monitored and controlled, if applicable. The heat treater shall have and maintain

135、 documented tolerances for the solutions. Refer to Process Tables, Section 5.0, for frequency of checks.2.14Are process control parameters monitored per frequencies specified in Process Tables? Process control parameters shall be monitored per frequencies specified in Process Tables. Refer to Proces

136、s Tables, Section 3.0. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log. Management review is required per Question 1.9.2.15Are In-Process / Fina

137、l Test Frequencies performed as specified in Process Tables?In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables, Section 4.0.2.16Is product test equipment verified?Product test equipment shall be verified. Test equipment shall be verified/ca

138、librated per applicable customer-specific standard or per an applicable consensus standard such as those published by ASTM, DIN, EN, ISO, JIS, NIST, SAE etc. Verification/calibration results shall be internally reviewed, approved, and documented. Refer to Process Tables, Section 1.0, for frequencyof

139、 checks. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 26For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Proc

140、ess Assessment3.1Do furnaces, generators, and quench systems have proper process control equipment?The heat-treat furnaces, generators, and quench systems shall have proper process controls and related equipment. Examples include temperature, carbon potential/dew point, gas flows, quench montoring s

141、ystem including agitation, temperature control and quenching oil analysis, etc. as listed in the applicable Process Tables, Section 1.0.3.2Are process equipment calibrations and/or verification certified, posted, and current? The calibration and certification of the process equipment shall be checke

142、d at regular specified intervals. Refer to the applicable Process Tables, Sections 1.0 and 2.0, for equipment calibration or certification time tables.3.3Are thermocouples & protection tubes checked or replaced per Process Tables?The thermocouples and protection tubes shall be checked or replaced in

143、 compliance to a preventive maintenance schedule. Refer to the applicable Process Tables, Section 2.0.3.4Are temperature uniformity surveys performed per requirements in Process Tables? Temperature uniformity surveys shall be conductedper the requirements in the applicable Process Tables, Section 2.

144、0. The frequency reductions allowed in AMS 2750 are not allowed under this document. Certain furnace designs, e.g., rotary retorts preclude direct temperature profiles. Indirect product studies are acceptable for furnaceswhere temperature uniformity studies are not possible.3.5Is the variation of th

145、e furnace controlled thermocouple from set point within the requirements in the Process Table?The variation between the furnace-control thermocouple and the set point temperature shall be within the limits defined in the applicable Process Tables, Section 2.0. This does not apply to the first zone o

146、f a multi-zone continuous furnace.3.6Are the process & equipment alarm checks being tested quarterly or after any repair or rebuild? The heat treater shall have a list of heat treat process and equipment alarms. These alarms shall be independently tested quarterly at a minimum, and after any repair

147、or rebuild. These checks shall be documented. Section 3 - EquipmentSpecial Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 27For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds

148、Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment3.7Are generators and furnace atmospheres continuously monitored, automatically controlled, and documented?Generator and furnace atmosphere carbon potential/dew point shall be continuously monitored, automatically controlled, an

149、d documented. This requirement is specific to Process Table 1, Sections 1.0 and 3.0, for carburizing, carbontiriding, and neutral hardening. Continuous monitoring and automatic control of the carbon potential/dew point is required for all generators and atmosphere furnaces except rotary retort and s

150、haker furnaces that preclude in situ control and monitoring. This requirement is specific to carburizing, carbonitriding, and neutral hardening. If generators are not used, the flow rates of the supplied atmosphere gases shall be monitored and controlled. The assessor shall verify the effectiveness

151、of the atmosphere control system per customer requirement, the heat treaters control plan, and internal procedures. The atmosphere control system shall maintain the atmosphere dew point/carbon potential set point within the parameters specified in the control plan or internal procedures. The heat tr

152、eater shall have a back-up method of checking the carbon potential/ Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 28For Ford Internal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds

153、 Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment3.8When the back-up verification check of the atmosphere does not agree or correlate within pre-established limits with the primary control method (carbon potential/dew point reading), is correlation of the carbon-bearing atmos

154、phere to the primary control method re-established?This issue is specific to Process Table 1, carburizing, carbonitriding, and neutral hardening. When the back-up verification check of the atmosphere does not agree or correlate within pre-established limits with the primary control method (carbon po

155、tential/dew point reading), the heat treater shall resolve the out-of-limit discrepancy. The back-up atmosphere monitoring system reading and the automatically controlled atmosphere dew point/carbon potential reading shall be maintained within the correlation limits specified in the control plan or

156、internal procedures. These range tolerances vary with the specific heat treat process and the equipment used. The heat treater shall make appropriate technical adjustments and corrections and then re-establish/demonstrate the correlation of the actual atmosphere carbon potential/dew point reading to

157、 the primary control and back-up atmosphere reading. The range tolerances for correlation between the two readings shall be in the control plan or internal procedures. The back-up carbon potential/dew point reading shall be established usin Carbon bar or slug Shim stock 3-gas analyzer Dew point Hot

158、wire resistanceSpecial Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 29For Ford Internal Use Only Question NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Tre

159、at Process Assessment3.9Are all ammonia lines equipped with quick disconnects or a three valve fail safe vent system?All ammonia lines to furnaces shall be equipped with quick disconnects or a three-valve fail-safe vent system. Normal valves may allow ammonia to leak through even when they are close

160、d. This can be undesirable and detrimental in heat treat processes not specifying/requiring ammonia. A quick disconnect shall be present in any ammonia line going to a furnace. This line shall be disconnected after carbonitriding (or any other process using ammonia) before another heat treating oper

161、ation not specifying/using ammonia begins. An alternative three-valve ammonia fail-safe vent system is permitted. See the definition “Three Valve Fail-Safe Vent” and diagram in the glossary. Documentation shall show when ammonia lines are disconnected for non-ammonia bearing atmosphere processes.3.1

162、0For fasteners and small metal parts, is a minimum of 3 hours allocated for an oxidizing burn-out prior to processing product not requiring ammonia?This is applicable to fasteners and small metal parts. The heat treater shall perform a minimum 3 hours oxidizing burn-out prior to processing product n

163、ot requiring ammonia as an addition. Ammonia pick-up can be undesirable in parts and heat treat processes not specifying/requiring ammonia as an addition. Log book, data logger, or other records shall document the actual oxidizing burn-out time and that sufficient time has been allocated to remove a

164、mmonia from the furnace prior to processing parts in heat treat processes not specifying ammonia.3.11Do all atmosphere furnaces and generators have flow scopes or flow meters for all gases?All atmosphere furnaces and generators (output trim/adjustment gas) shall have flow scopes or flow meters for a

165、ll gases. Flow scopes and meters shall be periodically serviced per the heat treaters preventive maintenance program. Cleaning and proper re-assembly procedures shall be documented. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 30For Ford Int

166、ernal Use OnlyQuestion NumberQuestionRequirements / GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment3.12For threaded fasteners, are all continuous belt furnaces equipped with sight glass inspection ports and infra

167、red pyrometers at discharge end of the hardening furnace? Infrared temperature pyrometers are required at the exit end of continuous belt furnaces running threaded fasteners to monitor for under temperature parts. The temperature alarm shall be within 28oC (50oF) of the furnace set point temperature

168、. Results shall be strip charted or continuously data logged. Infrared (IR) units shall be calibrated annually at a minimum and certified. All sight glasses shall be cleaned per the preventive maintenance schedule.3.13Is salt chemistry in the austenitizing salt bath monitored?Applicable to ferritic-

169、nitrocarburizing, austempering, and neutral hardening in salt.The heat treater shall check the salt chemistry in the austenitizing salt bath, or part decarburization, daily. Refer to the applicable Process Tables, Section 3.0, for frequency of checks.3.14Is the quenching medium analyzed?The heat tre

170、ater shall periodically have the quenching medium analyzed for specific quenchingcharacteristics, e.g., cooling curve, water content, salt concentration, as specified in the applicable Process Tables, Section 5.0. The quench media characteristic tolerances shall be specified by the quench medium sup

171、plier or the heat treater. Analysis shall be reviewed for conformance by the heat treater. This review shall be documented.Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 31For Ford Internal Use OnlyQuestion NumberQuestionRequirements / Guidanc

172、eObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAssessmentSpecial Process: Heat Treat Process Assessment3.15Is the positioning of each part being controlled?A method to detect proper part position, such as the use of proximity switches, optical sensors, mechanical probes, etc

173、., is required for each part.3.16Does the heat treater control the energy or power for each part?The heat treater shall control the energy or power for each part. A signature monitor for each machine is preferred. A signature monitor gives the energy unit (voltage, kilowatt, etc.) vs. time or distan

174、ce (for scanning systems). An energy monitor or equivalent is acceptable if approved by the design authority.3.17Does the supplier have a coil management system? Coil refers to the heating coil and the quench plenum.The heat treater shall have a coil management system. Coil refers to the heating coi

175、l and the quench plenum. Spare coils for each part shall be available on-site. Coils shall conform to the approved original design. Engineering change approval from the customer is required whenever the coil design is changed.3.18Is quench system automatic?The quench system shall be an automatic ope

176、ration. No manual quenching is allowed unless specifically approved by the design authority. Quenching shall be automatically initiated and controlled.3.19Does each lot of parts have first piece set-up?The heat treater shall perform first piece set-up for each lot of partsFOR INDUCTION HEAT TREATING

177、 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 32For Ford Internal Use Only Instructions for completing the Job Audit The organization is to complete a minimum of one heat treat part job audit during each assessment. This should be done prefe

178、rably on a part identified for one of the customers requiring compliance to this document. More part job audits may be done if time permits. Preferably, safety or critical parts should be audited. This may not be easily determined with fasteners, especially if the fastener manufacturer does not iden

179、tify the end customer (auto manufacturer, tier one, etc.). It is recommended that the job audit be performed at the end of the heat treat system assessment. The job audit is not the only or main focus of the HTSA. The other three sections on Management Responsibility and Quality Planning, Floor and

180、Material Handling Responsibility, and Equipment are equally if not even more important. The job audit of one part, one heat process, and one furnace is not sufficient to use as a basis to complete the other sections of the complete HTSA. The job audit is a compliance type audit/review of a specific

181、part and its related paperwork and processing, including heat treat equipment and processing records for that job from the beginning receipt of a part through processing in the heat treat operation and inspection to packaging. Parts shall be taken from the shipping area at the dock or the end of the

182、 heat treat operation. If an automotive manufacturers part is not available or identifiable, then parts from other customers requiring compliance with this document shall be done. The part or lot checked shall represent a major heat treat operation such as quench and tempering, carburizing and tempe

183、ring, induction hardening for steel, solution treating and aging of aluminum, etc. In subsequent heat treat system assessments, different parts and heat treat processes shall be checked. The specific heat treat processing parameters (applies to 4.7 in the Job Audit) that are required in the job audi

184、t shall be added to the job audit form. This can be done by reviewing the customer specification(s), the Control Plan, the PFMEA, 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 Heat

185、 Treat System Assessment for the actual job/heat treat process being reviewed for compliance. The heat treat and furnace records for the actual time frame/shift etc. that the job was processed shall also be checked. The actual furnace equipment and instrumentation certification shall be verified as

186、being in compliance to the appropriate equipment requirements in the equipment section. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 33For Ford Internal Use OnlySection 4 - Job AuditJob Identity:Customer:Purchase Order:Order Number:Part Numb

187、er:Part Description:Material:Heat Treat Requirements:Clause #Job Audit ClauseHTSA Clause #Customer or Internal RequirementJob (Shop) Order or Reference Documentation RequirementActual Condition (Objective Evidence)Pass / Fail / N/A4.1Are contract review, APQP, PFMEA, Control plans, etc., performed b

188、y competent individuals? 1.21.31.41.174.2Does the heat treat facility have the customer specifications for the part?1.54.3Is a shop traveler created to meet customer requirements?1.62.14.4Is material identification (part numbers, lot numbers, heat numbers, contract numbers, etc.) maintained througho

189、ut the heat treat process?2.22.32.44.5Is there documented evidence of Receiving Inspection?2.14.6Are the Loading / Racking requirements identified?1.62.7 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 34For Ford Internal Use OnlySection 4 - Jo

190、b AuditJob Identity:Customer:Purchase Order:Order Number:Part Number:Part Description:Material:Heat Treat Requirements:Clause #Job Audit ClauseHTSA Clause #Customer or Internal RequirementJob (Shop) Order or Reference Documentation RequirementActual Condition (Objective Evidence)Pass / Fail / N/A4.7

191、Is the proper recipe or process specification (cycle times, temperature, atmosphere, etc.) used? Refer to Process Tables, Section 3.0, for specific parameters. List parameters that were verified in this audit in the spaces provided below.1.51.62.12.142.15Special Process: Heat Treat System Assessment

192、 CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 35For Ford Internal Use OnlySection 4 - Job AuditJob Identity:Customer:Purchase Order:Order Number:Part Number:Part Description:Material:Heat Treat Requirements:Clause #Job Audit ClauseHTSA Clause #Customer or Internal RequirementJob (Shop)

193、Order or Reference Documentation RequirementActual Condition (Objective Evidence)Pass / Fail / N/A4.8What are the product inspection requirements?2.154.8.1Requirement: (1)Test Method:Test frequency or quantity:Selection of samples:Specification 4.8.2Requirement: (2)Test Method:Test frequency or quan

194、tity:Selection of samples:Specification 4.8.3Requirement: (3)Test Method:Test frequency or quantity:Selection of samples:Specification 4.8.4Requirement: (4)Test Method:Test frequency or quantity:Selection of samples:Specification Special Process: Heat Treat System Assessment CQI-9 36 Issue: 1.00, Da

195、ted 3/2006 Replaces: N/A, Dated: N/A 36For Ford Internal Use OnlySection 4 - Job AuditJob Identity:Customer:Purchase Order:Order Number:Part Number:Part Description:Material:Heat Treat Requirements:Clause #Job Audit ClauseHTSA Clause #Customer or Internal RequirementJob (Shop) Order or Reference Doc

196、umentation RequirementActual Condition (Objective Evidence)Pass / Fail / N/A4.9Were appropriate process steps signed off? 1.42.22.32.144.10Were all inspection steps, as identified in APQP, performed?1.21.44.11Were steps/operations performed that were not identified during APQP?1.21.41.64.12If additi

197、onal steps were performed, were they authorized?1.21.41.61.111.174.13Does the governing specification allow reprocessing or rework?1.114.14If the order was certified, did the certification accurately reflect the process performed?2.142.154.15Was the certification signed by an authorized individual?1

198、.174.16Are the parts and containers free of foreign objects or contamination?2.62.11Operator or Inspector ResponsibilitiesSpecial Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 37For Ford Internal Use OnlySection 4 - Job AuditJob Identity:Customer:Pur

199、chase Order:Order Number:Part Number:Part Description:Material:Heat Treat Requirements:Clause #Job Audit ClauseHTSA Clause #Customer or Internal RequirementJob (Shop) Order or Reference Documentation RequirementActual Condition (Objective Evidence)Pass / Fail / N/APackaging Requirements4.17Are packa

200、ging requirements identified? 2.94.18Are parts packaged to minimize mixed parts (parts packed over height of container)?2.62.11Shipping Requirements4.19Were the parts properly labeled?2.32.9 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 38For

201、 Ford Internal Use Only APPENDIX A PROCESS TABLES Process Table 1: Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging 42 Process Table 2: Nitriding (Gas) and Ferritic-Nitorcarburizing (Gas or Salt)44Process

202、 Table 3: Aluminum Heat Treatment49Process Table 4: Induction Heat Treating52 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 39For Ford Internal Use OnlySP-HTSA Clause #Batch FurnaceContinuousFurnace *Generators1.0PROCESS AND TEST EQUIPMENT RE

203、QUIREMENTS1.13.1All furnaces, generators and quench systems shall have temperature indicating instruments.YesYesYes1.23.1Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc.YesYesYes1.31.18A program

204、for furnace and generator burnout is required (applies to carbon bearing atmospheres).YesYesYes1.43.2Furnace weigh scales shall be calibrated quarterly at a minimum.YesYesN/A1.53.2Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify c

205、arbon potential in furnaces, shall be calibrated annually at a minimum.-1.63.2Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use.Yes-1.73.2Verification of calibraion of 3-gas analzers with zero gas and span gas shall be performed

206、weekly at a minimum. -1.83.2Oxygen probe controllers shall be calibrated quarterly at a minimum.YesYesYes1.92.16All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.-1.102.16Files shall be verified da

207、ily (or prior to use) with provers per SAE J864.-1.113.2Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manfacturers requirements) at a minimum.-All requirements given below are subordinate t

208、o customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When perfoming the job audit, the audito

209、r shall verify heat treater is conforming to the customers requirements.* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.* Does not apply to furnaces operating below 760C (1400F).PROCESS TABLE 1 - Carburizing / Carbonitriding / Carbon Correction /

210、 Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 40For Ford Internal Use OnlySP-HTSA Clause #Batch FurnaceContinuousFurnace *GeneratorsAll requirement

211、s given below are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When perf

212、oming the job audit, the auditor shall verify heat treater is conforming to the customers requirements.* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.* Does not apply to furnaces operating below 760C (1400F).PROCESS TABLE 1 - Carburizing / Carbo

213、nitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging2.0PYROMETRY2.13.23.3Thermocouples and calibration of thermocouples shall conform to AMS 2750.YesYesYes2.23.23.3Instrument Calibration per AMS 2750 shall be quarterly at a min

214、imum. Frequency reductions per AMS 2750 are not allowed.YesYesYes2.33.23.3System Accuracy Test (SAT): refer to AMS 2750 for procedures. SAT frequency shall be monthly for equipment operating above or at 760C (1400 F) and quarterly for equipment operating below 760C (1400 F). Maximum allowable SAT er

215、ror is +/- 10 F (+/- 5 C). Frequency reductions per AMS 2750 are not allowed.Protection Tubes shall be visually checked at same frequency as thermocouples.YesYesYes2.43.4Temperature Uniformity Survey (TUS): refer to AMS 2750 for procedures. TUS frequency shall be annual and after major rebuild. Temp

216、erature uniformity tolerance for hardening furnaces shall be +/- 14 C (25 F). Temperature uniformity tolerance for tempering furnaces shall be +/- 11 C (20 F). Frequency reductions per AMS 2570 are not allowed.YesYesN/A2.53.5Recorded temperature(s) for austenitizing processes shall be controlled wit

217、hin +/- 9C (15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).YesYesN/A2.63.5Recorded temperature(s) for tempering and precipitation hardening processes shall be cont

218、rolled within +/- 6C (10F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).YesYesN/A2.73.2Infrared pyrometers shall be calibrated to a black body furnace annually.N/ASpe

219、cial Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 41For Ford Internal Use OnlySP-HTSA Clause #Batch FurnaceContinuousFurnace *GeneratorsAll requirements given below are subordinate to customer specific requirements. Reduction of minimum requirements

220、 require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When perfoming the job audit, the auditor shall verify heat treater is conforming to the customers requirem

221、ents.* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.* Does not apply to furnaces operating below 760C (1400F).PROCESS TABLE 1 - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Prec

222、ipitation Hardening - Aging3.0PROCESS MONITOR FREQUENCIES3.11.42.14Monitor primary temperature control instrument(s).Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementEach lot or continuous recording with sign-off every 2 hours. Alarm syste

223、ms satisfy the sign-off requirementEach Shift3.21.42.143.7Monitor generator atmospheresN/AN/AContinuous3.31.42.143.7Monitor primary furnace atmosphere control(s)*.Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementContinuous recording with sign-off every

224、2 hours. Alarm systems satisfy the sign-off requirementN/A3.41.42.143.7Verify primary atmosphere control method by back-up method*.DailyDailyDaily3.51.42.143.13For salt baths: check salt chemistry (soluble oxides) in salt baths or decarburization on the parts.DailyDailyN/AMonitor condition of quench

225、 media - TemperatureEach batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementEach lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementN/A- Quench LevelDailyDailyN/A- Agitation- Daily visual check

226、is required- Monitor each load in the absence of an alarm system.- Daily visual check is required- Monitor every 2 hrs in the absence of an alarm systemN/A3.71.42.14Monitor time in furnace, cycle time or belt speed Each batch Twice/shift & after any change in the belt speedN/A3.81.42.7Monitor load s

227、ize or fixturing or loading rate as applicable.Each batch Twice/shift & after any change in loading rateN/A3.91.42.12Quench Delay Time -Alarm system shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.Each batch Each basket for pusher-t

228、ype continuous furnaces. Not applicable for belt furnaces. N/A3.61.42.12 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 42For Ford Internal Use OnlySP-HTSA Clause #Batch FurnaceContinuousFurnace *GeneratorsAll requirements given below are subo

229、rdinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When perfoming the job audit, t

230、he auditor shall verify heat treater is conforming to the customers requirements.* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.* Does not apply to furnaces operating below 760C (1400F).PROCESS TABLE 1 - Carburizing / Carbonitriding / Carbon Cor

231、rection / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging4.0IN-PROCESS/FINAL TEST FREQUENCIES4.11.42.15MicrostructureDaily per furnaceDaily per furnaceN/A4.21.42.15Surface hardnessEach batchEvery 2 hours minimumN/A4.31.42.15Core hardness (when specified)

232、Each batchEvery 4 hoursN/A4.41.42.15Case depth (when specified) Each batchEvery 4 hoursN/A5.0QUENCHANT AND SOLUTION TEST FREQUENCIESPolymer Quench Media- Concentration Daily DailyN/A- Quenchability Check; e.g., cooling curve, viscosity, or titration Semiannual SemiannualN/AWater Quench Media- Suspen

233、ded solids Semiannual SemiannualN/ASalt Media- Analysis & Contaminants (for salts not used in quenching)Semiannual SemiannualN/A- Analysis & Contaminants (for salts not used in quenching)MonthlyMonthlyN/ABrine or Caustic Quench Media- Concentration and/or Specific Gravity Daily DailyN/A- Suspended s

234、olids Semiannual SemiannualN/AOil Quench Media- Water content, suspended solids, viscosity, cooling curve, total acid, and flash point.QuarterlyQuarterlyN/ARust Preventive - Soluble Oil- Concentration2x / week2x / weekN/AWashers- Concentration of cleanerDailyDailyN/A- Temperature of solution (requir

235、ed if temperature is specified to be above ambient temperature).Each shiftEach shiftN/A2.123.142.123.142.123.142.123.145.15.25.35.45.55.45.52.112.132.123.14Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 43For Ford Internal Use OnlySP-HTSA Clau

236、se #Batch FurnaceContinuousFurnace*GeneratorsSalt Bath1.0PROCESS AND TEST EQUIPMENT REQUIREMENTS1.13.1All furnaces, generators and quench systems shall have temperature indicating instruments.YesYesYesYes1.23.1Continuous strip charts and/or data loggers are required for temperature and carbon monito

237、ring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc.YesYesYesYes1.31.18A program for furnace and generator burnout is required. Not required for retort gas nitriding.YesYesYesN/A1.43.12Salt chemistry (soluble oxides) in salt baths used for austenitizing, or decarburization on the parts, s

238、hall be checked daily.N/AN/AN/AYes1.53.2Furnace weigh scales shall be calibrated quarterly at a minimum.YesYesN/AN/A1.63.2Dew pointers and gas analyzers, used to verify proper atmosphere in furnaces, shall be calibrated annually at a minimum.-1.72.16All hardness test equipment (for each scale used)

239、shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.-1.82.16Files shall be verified daily (or prior to use) with provers per SAE J864.-1.93.2Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (wi

240、th distilled water) and calibrated annually (per manfacturers requirements) at a minimum.-All requirements given below are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The

241、 customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers requirements.* Continuous furnace frequencies are per lot (work order) or as specified, whichever is mor

242、e frequent.PROCESS TABLE 2 - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt) Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 44For Ford Internal Use OnlySP-HTSA Clause #Batch FurnaceContinuousFurnace*GeneratorsSalt BathAll requireme

243、nts given below are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When pe

244、rforming the job audit, the auditor shall verify heat treater is conforming to the customers requirements.* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.PROCESS TABLE 2 - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)2.0PYROMETRY 2.

245、13.23.3Thermocouples and calibration of thermocouples shall conform to AMS 2750.YesYesYesYes2.23.23.3Instrument Calibration per AMS 2750 shall be quarterly at a minimum. Frequency reductions per AMS 2750 are not allowed.YesYesYesYes2.33.23.3System Accuracy Test (SAT): refer to AMS 2750 for procedure

246、s. SAT frequency shall be monthly. Maximum allowable SAT error is +/- 10 F ( +/- 5 C). Frequency reductions per AMS 2750 are not allowed.Protection tubes shall be visually checked at same frequency as thermocouples.YesYesYesYes2.43.4Temperature Uniformity Survey (TUS): refer to AMS 2750 for procedur

247、es. TUS frequency shall be annual and after major rebuild. Temperature uniformity tolerance shall be +/- 9 C (15 F). Frequency reductions per AMS 2570 are not allowed.YesYesN/AYes2.53.5Recorded temperature(s) shall be controlled within +/- 9C (15F) of the set point as evidenced by continuous recordi

248、ng pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).YesYesN/AYes2.63.2Infrared pyrometers shall be calibrated to a black body furnace annually .Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Re

249、places: N/A, Dated: N/A 45For Ford Internal Use OnlySP-HTSA Clause #Batch FurnaceContinuousFurnace*GeneratorsSalt BathAll requirements given below are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be

250、on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers requirements.* Continuous furnace frequencies are per lot (work order) or as

251、 specified, whichever is more frequent.PROCESS TABLE 2 - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)3.0PROCESS MONITOR FREQUENCIES3.11.42.14Monitor primary temperature control instrument(s).Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign

252、-off requirementEach lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementEach ShiftEvery 2 hrs & after any change3.21.42.143.7Monitor generator atmospheres, if applicable.N/AN/AContinuousN/A3.31.42.143.7Monitor primary furnace atmosphere control(s).

253、Each batch (rotary furnaces only) or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementContinuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementN/ADaily3.41.43.7Dissociation of ammonia shall be checked in gas nitrid

254、ing.Each batch and every 4 hours minimumEvery 4 hoursDailyN/A3.51.43.7Gas ratios for ferritic nitrocarburizing shall be checked.Each batchEvery 2 hours minimum3.61.42.143.13Check salt chemistry (soluble oxides) in salt baths used for austenitizing, or decarburization on the parts.N/AN/AN/ADaily3.71.

255、42.12Monitor condition of quench media if applicable:- TemperatureEach batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementEach lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementN/AEach batch or

256、 continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement- Quench LevelDailyDailyN/ADaily Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 46For Ford Internal Use OnlySP-HTSA Clause #Batch FurnaceContinuou

257、sFurnace*GeneratorsSalt BathAll requirements given below are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection t

258、esting, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers requirements.* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.PROCESS TABLE 2 - Nitriding (Gas) and Ferritic-Nitr

259、ocarburizing (Gas or Salt)- Agitation- Daily - Monitor each load in the absence of an alarm system.- Daily - Monitor every 2 hrs in the absence of an alarm systemN/ADaily3.81.42.14Monitor time in furnace, cycle time or belt speed Each batch Twice/shift & after any change in the belt speedN/A Each ba

260、tch 3.91.42.7Monitor load size or fixturing or loading rate as applicable.Each batch Twice/shift & after any change in loading rateN/A Each batch 3.101.42.12Quench Delay Time if applicable -Alarm system shall be based on the time that the load exits the furnace to the time the load is at the bottom

261、of the quench tank.Each batch Each basket if applicableN/A Each batch 4.0IN-PROCESS/FINAL TEST FREQUENCIES 4.11.42.15MicrostructureDaily per furnaceDaily per furnace N/ADaily per furnace4.21.42.15Surface hardnessEach batchEvery 2 hours minimumN/A Each batch4.31.42.15Core hardness (when specified)Eac

262、h batchEvery 4 hoursN/A Each batch4.41.42.15Case depth (when specified) Each batchEvery 4 hoursN/A Each batchSpecial Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 47For Ford Internal Use OnlySP-HTSA Clause #Batch FurnaceContinuousFurnace*GeneratorsSa

263、lt BathAll requirements given below are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequ

264、encies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers requirements.* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.PROCESS TABLE 2 - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or

265、Salt)5.0QUENCHANT AND SOLUTION TEST FREQUENCIESQuench Media Controls If ApplicablePolymer Quench Media- Concentration Daily DailyN/AN/A- Quenchability Check; e.g., cooling curve, viscosity, or titration Semiannual SemiannualN/AN/AWater Quench Media- Suspended solids Semiannual SemiannualN/AN/ASalt M

266、edia- Analysis & ContaminantsN/AN/AN/AMonthlyBrine or Caustic Quench Media- Concentration and/or Specific Gravity Daily DailyN/AN/A- Suspended solids Semiannual SemiannualN/AN/AOil Quench Media- Water content, suspended solids, viscosity, cooling curve, total acid, and flash point.QuarterlyQuarterly

267、N/AN/ARust Preventive - Soluble Oil- Concentration2x / week2x / weekN/A2x / weekWashers- Concentration of cleanerDailyDailyN/ADaily- Temperature of solution (required if temperature is specified to be above ambient temperature).Each shiftEach shiftN/AEach shift5.55.65.15.25.45.72.123.142.123.142.123

268、.142.123.142.132.112.123.145.3 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 48For Ford Internal Use OnlySP-HTSA Clause #Batch Solution Treating and Aging FurnacesContinuous Solution Treating and Aging FurnacesAnnealing Furnace1.0PROCESS AND

269、TEST EQUIPMENT REQUIREMENTS1.13.1All furnaces and quench systems shall have temperature indicating instruments.YesYesYes1.23.1Continuous strip charts and/or data loggers are required for temperature sensors.YesYesYes1.32.16All hardness test equipment (for each scale used) shall be calibrated semi-an

270、nually minimum, and verified daily minimum per the applicable ASTM standard.-1.43.2Furnace weigh scales shall be calibrated quarterly at a minimumYesYesYes1.53.2Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibra

271、ted annually (per manfacturers requirements) at a minimum.-All requirements given below are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional r

272、equirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers requirements.Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.PROCESS TABLE 3 - Alum

273、inum Heat TreatingSpecial Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 49For Ford Internal Use OnlySP-HTSA Clause #Batch Solution Treating and Aging FurnacesContinuous Solution Treating and Aging FurnacesAnnealing FurnaceAll requirements given below

274、 are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the jo

275、b audit, the auditor shall verify heat treater is conforming to the customers requirements.Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.PROCESS TABLE 3 - Aluminum Heat Treating2.0PYROMETRY 2.13.23.3Thermocouples and calibration of thermocouples

276、shall conform to AMS 2750.YesYesYes2.23.23.3Instrument Calibration per AMS 2750 shall be quarterly at a minimum. Frequency reductions per AMS 2750 are not allowed.YesYesYes2.33.23.3System Accuracy Test (SAT): refer to AMS 2750 for procedures. SAT frequency shall be monthly for solution treating and

277、aging furnaces and quarterly for annealing furnaces. Maximum allowable SAT error is +/- 3 C (+/- 5 F ). Frequency reductions per AMS 2750 are not allowed.Protection tubes shall be visually checked at same frequency as thermocouples.YesYesYes2.43.4Temperature Uniformity Survey (TUS): refer to AMS 275

278、0 for procedures. TUS frequency shall be quarterly and after major rebuild.Temperature uniformity tolerance for solution treating and aging furnaces shall be +/- 6 C (+/- 10 F). Temperature uniformity tolerance for annealing furnaces shall be +/- 14 C (+/- 25 F). Frequency reductions per AMS 2750 ar

279、e not allowed.YesYesYes2.53.5Recorded temperature(s) shall be controlled within +/- 6C (10F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).YesYesN/A2.63.5Recorded temp

280、erature(s) shall be controlled within +/- 9C (15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).N/AN/AYes2.73.2Infrared pyrometers shall be calibrated to a black body

281、 furnace annually Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 50For Ford Internal Use OnlySP-HTSA Clause #Batch Solution Treating and Aging FurnacesContinuous Solution Treating and Aging FurnacesAnnealing FurnaceAll requirements given below

282、 are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the jo

283、b audit, the auditor shall verify heat treater is conforming to the customers requirements.Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.PROCESS TABLE 3 - Aluminum Heat Treating3.0PROCESS MONITOR FREQUENCIES3.11.42.14Monitor primary temperature c

284、ontrol instrument(s).Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementEach lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementEach batch or continuous recording with sign-off every 2 hour

285、s. Alarm systems satisfy the sign-off requirementMonitor condition of quench media- Heat treater shall specify temperature range based on product form and material. Temperature shall be monitored as noted.Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-

286、off requirementEach lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirementN/A- Quench LevelDailyDailyN/A- Agitation- Daily visual check is required- Monitor each load in the absence of an alarm system.- Daily visual check is required- Monitor every 2

287、hrs in the absence of an alarm systemN/A3.31.42.14Monitor process cycle time Each batch Twice/shift & after any change in the indexing speed Each batch 3.41.42.7Monitor load size or fixturing as applicable.Each batch Twice/shift & after any change in loading rateEach batch 3.51.42.12Quench Delay Tim

288、e -Quench delay time shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.Each batch Each loadN/A4.0IN-PROCESS/FINAL TEST FREQUENCIES 4.11.42.15Hardness or tensile testing (post aging), Each batchEvery 4 hoursEach batch or every 4 hours

289、for continuous furnaces5.0QUENCHANT AND SOLUTION TEST FREQUENCIESPolymer Quench Media- Concentration Daily DailyN/A- Suspended solids Semiannual SemiannualN/A- Quenchability Check; e.g., cooling curve, viscosity, or titration Semiannual SemiannualN/AWater Quench Media- Suspended solids Semiannual Se

290、miannualN/AWashers- Concentration of cleanerDailyDailyDaily- Temperature of solution (required if temperature is specified to be above ambient temperature).Each shiftEach shiftEach shift3.21.42.125.32.112.123.142.123.145.15.2Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/20

291、06 Replaces: N/A, Dated: N/A 51For Ford Internal Use OnlySP-HTSA Clause #Per Coil1.0PROCESS AND TEST EQUIPMENT REQUIREMENTS1.1-Per customer requirement1.22.16All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable AST

292、M standard.-1.32.16Files shall be verified daily (or prior to use) with provers per SAE J8641.43.2Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified each shift (with distilled water) and calibrated annually (per manfacturers requirements) at a minimum.

293、-PROCESS TABLE 4 - Induction Heat TreatingAll requirements given below are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g.

294、, inspection testing, greater frequencies, etc. When perfoming the job audit, the auditor shall verify heat treater is conforming to the customers requirements. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 52For Ford Internal Use OnlySP-HTSA

295、 Clause #Per CoilPROCESS TABLE 4 - Induction Heat TreatingAll requirements given below are subordinate to customer specific requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional re

296、quirements, e.g., inspection testing, greater frequencies, etc. When perfoming the job audit, the auditor shall verify heat treater is conforming to the customers requirements.2.0PYROMETRY 2.13.2Infrared pyrometers shall be calibrated to a black body furnace annually 3.0PROCESS MONITORING FREQUENCIE

297、SMonitor condition of quench media if applicable - TemperatureAlarm system for high and low temperature is required.- Quench LevelDaily- Quench Pressure and Flow- Quench pressure and flow may checked at manifold. Quench flow shall be checked visually at each coil.- In the absence of an alarm system,

298、 monitor every 2 hours or after any change3.21.42.14Monitor cycle time Check cycle time at start up and after any process change.3.31.42.143.16Monitor: 1) Volts or Amps, and2) KilowattsUse of an energy monitor or signature monitor satisfies 1) and 2)- this requirement applies to each power supply (n

299、ot per coil) - in the absence of an alarm system, monitor every 2 hours or after any changeAll process parameters shall be checked the beginning of every shift, tool change, or any equipment repair. In absence of process parameter alarms, also check process parameters at end of shift or lot (whichev

300、er is the greater frequency).3.11.42.12Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 53For Ford Internal Use OnlySP-HTSA Clause #Per CoilPROCESS TABLE 4 - Induction Heat TreatingAll requirements given below are subordinate to customer specifi

301、c requirements. Reduction of minimum requirements require approval from the customer (customer documentation shall be on file at the supplier).The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When perfoming the job audit, the auditor shall verify hea

302、t treater is conforming to the customers requirements.4.0IN-PROCESS/FINAL TEST FREQUENCIES Production Setup or Coil Change - Per Coil(1st Piece Inspection)4.41.42.15Induction pattern length1 part at start-up, end of production run, and every 4 hours minimum. 4.51.42.15Total or Effective Case depth1

303、part at start-up, end of production run, and 1 part per 8 hours minimum.4.61.42.15Surface hardness 1 part at start-up, end of production run, and every 4 hours minimum. 4.71.42.15Core hardness (when specified)1 part at start-up, end of production run, and every 4 hours minimum. 4.81.42.15Microstruct

304、ure1 part at start-up.5.0QUENCHANT AND SOLUTION TEST FREQUENCIESQuench Media Controls If ApplicablePolymer Quench Media- Concentration Once per day- Quenchability Check; e.g., cooling curve, viscosity, or titrationMonthlyWater Quench Media- Suspended solids QuarterlyBrine or Caustic Quench Media- Co

305、ncentration and/or Specific GravityMonthly- Suspended solids QuarterlyRust Preventive - Soluble Oil- Concentration2x / weekWashers- Concentration of cleanerDaily- Temperature of solution (required if temperature is specified to be above ambient temperature).Each shift2.123.145.35.45.52.112.132.123.1

306、42.123.145.15.2 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 54For Ford Internal Use Only Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 55For Ford Internal Use Only GLOSSARY AIAG Auto

307、motive Industry Action Group AMS - Aerospace Material Specifications APQP Advance Product and Quality Planning ASTM American Society for Testing and Materials Capability The total range of inherent variation in a stable process. (see the Statistical Process Control reference manual published by AIAG

308、). Control Plans Written descriptions of the system for controlling production parts or bulk materials and processes. They are written by organizations to address the important characteristics and engineering requirements of the product. Each part must have a Control Plan, but in many cases, “family

309、” Control Plans can apply to a number of parts produced using a common process. Refer to Advanced Product Quality Planning and Control Plan reference manual, ISO/TS 16949, and customer-specific requirements. Critical Spare Parts List A list of service parts critical for the operation of equipment. E

310、xtended delay in obtaining spare parts would result in unacceptable delays in the heat treat operation. Cross-Functional Team A team of employees that represent the different functions within an organization. The team will typically consist of an operator, process engineer, metallurgist, and quality

311、 personnel. The term “cross-functional” is synonymous with the term “multi-disciplinary.” Customer The recipient of the organizations or suppliers product or service. Customer Requirements This term refers to the requirements or specifications from the original equipment manufacturer (typically the

312、automobile company). These may be identified in the contract or purchase order, in engineering standards, parts specifications, etc. Design Authority The entity that controls the design (material specification and heat treat specification) of the part. Dew Pointer A meter especially suited for measu

313、ring the dew point of carbon-bearing atmospheres. Dew point is used to indirectly determine the carbon potential of the atmosphere. Energy Monitor An electronic monitor that measures and displays the actual energy delivered to the induction heating coil in kilowatt-seconds. Furnace Monitoring System

314、s A system that monitors the operation of the furnace. Heat Treater An organization that performs heat treating (see 2.2 Application) to production and/or service parts. The heat treating may be internal or “captive” to a manufacturing organization, or a separate commercial heat treating supplier. H

315、TSA Heat Treat System Assessment Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 56For Ford Internal Use Only IR Infrared Nonconforming Product Product that does not conform to the customer requirements or specifications. Oxidizing Burn-Out A p

316、rocess to remove any residual ammonia from the furnace. The process usually involves removing most of the carbon-bearing protective atmosphere and then introducing oxygen. Oxygen Probe An in-situ measuring probe that determines the partial pressure of oxygen in carbon-bearing atmospheres. This measu

317、rement provides an indirect measurement for the carbon potential of the atmosphere. PFMEA Process Failure Mode and Effects Analysis PPAP Production Part Approval Process Process Tables Tables in the HTSA that list the required process controls for the heat treat processes covered. These tables conta

318、in minimum requirements. Quenchability Check A measure of the cooling dynamics of the quench media. A quenchometer is the inspection machine that displays the cooling curve of the quench media. Quench Delay The time delay between the end of the heat treat cycle and the start of the quench operation.

319、 For furnace heat treating, this is period from the time the parts exit the furnace proper to the time the parts are at the bottom of the quench tank. For induction hardening systems, this is the time from the end of the heat cycle to the start of the quench flow (or when the parts enter a quench ta

320、nk). Quenching Medium The medium used to quench parts after heat treating, e.g., oil, water, polymer, and salt. Recipe This term is typically used when a computer-based system sets and controls the process parameters, e.g., temperature, cycle time, carbon potential. The recipe refers to the settings

321、 of the process parameters. Reprocessing Any process that is performed on nonconforming product so that it will meet the specified requirements. Responsibility Matrix A responsibility matrix defines the designated personnel for all key functions. This matrix includes the primary and secondary design

322、ees. RPN Risk Priority Number A calculated number in the PFMEA. RPN is obtained by multiplying the Severity rating by the Occurrence rating by the Detection rating. SAE Society of Automotive Engineers Shop Traveler A document usually created in the receiving department for each batch or lot of parts

323、 received. The document defines the process routing of the parts. Signature Monitor An electronic monitor used to monitor induction heat treating systems. The monitor plots the energy unit, e.g., voltage or kilowatt, vs. time or distance. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.

324、00, Dated 3/2006 Replaces: N/A, Dated: N/A 57For Ford Internal Use Only Special Characteristics are product characteristics or manufacturing process parameters which can affect safety or compliance with regulations, fit, function, performance or subsequent processing of product. Refer to customer-sp

325、ecific requirements. Temper Delay The time delay from when the parts exit the quench tank to the time when the parts are placed in the tempering furnace. 3 (Three) Gas Analyzer An instrument that measures carbon monoxide, carbon dioxide, and methane in carbon-bearing atmospheres. This measurement pr

326、ovides an indirect measurement of the carbon potential of the atmosphere. Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 58For Ford Internal Use Only Three-Valve Fail-Safe Vent (for ammonia lines) An arrangement of three valves that prevents a

327、mmonia from inadvertently entering the furnace during carburizing or neutral hardening operations. The valves are arranged in such a way that, when the ammonia line to the furnace is shut off, any ammonia that might leak past the valve is vented to the atmosphere and thus prevented from entering the

328、 furnace. See the diagrams below. Furnace Valve 3 Furnace Valve 3 Vent Vent Valve 1 Valve 2 Valve 1 Valve 2 Figure 1 Valves 1 and 2 are opened to allow ammonia flow into the furnace. Figure 2 Valves 1 and 2 are closed to prevent ammonia flow to furnace. If Valve 2 inadvertently leaks, ammonia is ven

329、ted (Valve 3) to the atmosphere. Trap Points Areas in containers (baskets, fixtures, shipping boxes, etc.) or equipment that may inadvertently trap parts, allowing the potential for parts to be mixed between batches. Work Instructions Instructions that describe work conducted in one function in a co

330、mpany, e.g., setup, inspection, heat treat operation, process parameter tolerances, etc. The term “work instructions” is synonymous with the term “job instructions.” Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 59For Ford Internal Use OnlyAB

331、OUT AIAG Purpose Statement To provide an open forum where members cooperate in developing and promoting solutions that enhance the prosperity of the automotive industry. Our focus is to continually improve business processes and practices involving trading partners throughout the supply chain. Core

332、Values People Our strength comes from passionate and personally committed volunteers and staff. We provide an environment of integrity, trust, teamwork, and mutual respect to foster open, frank communication as we achieve consensus on industry needs and solutions. Innovation With a sense of urgency,

333、 we drive and support the development and implementation of common, leading-edge solutions that provide value to the automotive industry and its customers. Excellence We provide quality and excellence in all we do and how we do it. We do whats right for the industry! AIAG Organization AIAG is made u

334、p of a board of directors, an executive director, associate directors, a full-time staff, and volunteers serving on project teams. Under the direction of the executive director, associate directors along with the managing director, department managers, and program managers, plan, direct, and coordin

335、ate the associations activities. The executive director and loaned executives are on loan from member companies for varied lengths of time. AIAG Projects Volunteer committees focus on business processes or supporting technologies and methodologies. They conduct research and develop, publish, and pro

336、vide training on standards, conventions, standard business practices, white papers, and guidelines in the areas of automatic identification, CAD/CAM, EDI/electronic commerce, continual quality improvement, materials and project management, returnable containers and packaging systems, and transportat

337、ion/customs. AIAG - An Association Fostering Total Supply Chain Partnering Automotive Industry Action Group 26200 Lahser Road, Suite 200 Southfield, MI 48034 Phone: (248) 358-3570 Orders: (248) 358-3003 Fax: (248) 358-3253 Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006

338、 Replaces: N/A, Dated: N/A 60For Ford Internal Use Only MAINTENANCE REQUEST If you find an error or other changes that should be made to this publication, please complete this form and return it to the address below. PLEASE PRINT OR TYPE Name of Submitter: _ Date: _ Company:_ Company Address: _ Phon

339、e:_ Fax: _ E-mail:_ MAINTENANCE REQUEST (Use additional sheets if necessary) Page Number of Change: _ Document Currently Reads: _ _ _ Recommended Changes/Should Read:_ _ _ Recommended Additions: _ _ _ Reason for Change:_ _ Signature of Submitter:_ DISPOSITION (AIAG use only) Completed forms are file

340、d in the final document maintenance file. Program Owner Assigned to:_ Log #:_ Program Owners Recommendation: _ _ Final Disposition:_ _ Comments:_ _ Send completed form to the Publication Specialist at: Automotive Industry Action Group 26200 Lahser Road Suite 200 Southfield, MI 48034 Telephone: (248) 358-3570 Fax: (248) 358-3253 www.aiag.org Special Process: Heat Treat System Assessment CQI-9 Issue: 1.00, Dated 3/2006 Replaces: N/A, Dated: N/A 61