Cqi-9 pdf free download

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Refer to Process Tables, Section 3. Are 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 shall be trained 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 understood by equipment operators. These instructions shall address containment actions related to all elements of the heat-treating process, e.

Objective Evidence Are parts free from contaminants that would be detrimental to the heat treatment of the product? Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality.

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 floor, oil around quench tanks, inadequate plant lighting, smoke, etc.

X Work Instructions for emergency procedures are documented and available to each operator on the shop floor and in the computer database; The relevant document is titled "Contingency Plans". Training is documented in the Training Matrix.

X Plant cleanliness and housekeeping is the responsibility of each and every employee and, ultimately, each Shift Supervisor. The environmental and working conditions are evaluated regularly to ensure that they are conducive to maintaining employee health and welfare, as well as conducive to control of product and improving quality of product.

Many heat-treated parts are subjected to surface finish or appearance operations such as plating or coating after heat treatment. 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 process. All parts are washed between quench and temper. Note: Refer to the appropriate heat treater's requirements and specifications to determine acceptability.

Refer to Process Table, Section 5. Handling, storage, and packaging shall be adequate to preserve product quality. Equipment and material handling procedures are adequate to preserve packaging adequate to Some equipment includes conveyors and other moving components that product quality.

Other practices, such as stacking of overloaded containers, can also increase the risk of part damage. Are plant cleanliness, housekeeping, environmental and working conditions conducive to control and improved quality? The temperature, agitation, level, concentration if applicable , time in the quenchant, and additions shall be controlled to the heat treater's specifications. Refer to Process Tables, Sections 3.

Computer-monitoring equipment, with alarms and monitored, documented, and alarm logs, satisfy the verification requirement. Quench delay tolerance controlled? Temper delay time shall be specified by the heat treater for parts that are quenched and tempered, e. Oil is checked for quenchability quarterly for our rotary furnaces, since oil levels are continuously being replenished because of dragout. 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 documented tolerances for the solutions. Refer to Process Tables, Section 5. When required, solutions are made up and the concentrations are checked weekly, per tolerances listed in MSDS sheets. Process control parameters shall be monitored per frequencies specified in Process Tables.

Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e. Management review is required per Question 1. Process control parameters are monitored in real time on several computers in the plant, as well as the Data Acquisition System.

Final inspection and signoff of all parameters for each work order is done by the Shift Supervisor or Designee. Furnace logs are also used to record additional parameters not recorded on the Data Acquisition System.

X Testing frequencies meet or exceed specifications. See individual work order instructions and Work Orders for actual Test Frequencies for each order. Refer to Process Tables, Section 4. Is product test equipment verified? Product test equipment shall be verified. Refer to Process Tables, Section 1. Refer to the applicable Process Tables, service.

A calibrated portable 3-Gas Analyzer is available for verification certified, posted, and current? Sections 1. Refer to the applicable preventive maintenance schedule. Process Tables, Section 2. X Temperature uniformity surveys shall be conducted per the requirements in the applicable Process Tables, Section 2.

Certain furnace designs, e. Alternate test methods per Section 3. TUS studies are not required for Ion Nitriding. AMP's Rotary Furnaces: In lieu of temperature uniformity surveys or direct temperature profiles, Product studies are conducted to evaluate and correlate the CPK of the Surface Hardness versus the CPK of the Core Hardness, for additional information about the correlation of data and the effectiveness of the process.

X The variation between the furnace control thermocouple value and the set point temperature shall be within the limits defined in the applicable Process Tables, Section 2.

All control thermocouples in continuous furnaces are within specified tolerances, as are being verified by daily logging. X System alarms are checked quarterly and documented in the Preventive Maintenance Book. X The heat treater shall have a list of heat treat process and equipment alarms that, if not properly working, may have a high probablity of producing non-conforming product. Other alarms, including but not limited to safety-related, shall be checked per heat treater's requirement.

These alarm checks shall be documented. Recorded dew point shall be controlled within acceptable limits specified in the control plan or internal procedures. Rotary Furnaces: Generators and furnace atmospheres are monitored via dew points and gas flow rates, which are recorded at the start of each and every work order.

A portable 3-Gas Analyzer is available for verifying the dew point, while furnace-mounted carbon probes provide real-time, If generators are not used, the flow rates of the supplied atmosphere gases continuous monitoring of the atmosphere in the furnace shell to the Data shall be monitored and controlled.

Acquisition System. The automatic and continuous atmosphere control system shall consist of sensors such as oxygen probes or on-line Infrared IR gas analysis. Examples are dew point, electrical wire resistance, gas analysis, shim stock, carbon bar, etc.

See Process Tables, Sect. These range tolerances vary with the specific heat treat process and the equipment used. The range tolerances for correlation between the two readings shall be in the control plan or internal procedures. The heat treater shall show evidence that ammonia lines were disconnected for non-ammonia bearing atmosphere processes. X A minimum 3-hour oxiding burn-out is performed prior to processing product not requiring ammonia as an addition.

End times for previous process and part processed are recorded, as well as the start time for the next process and the specific part processed. The Furnace Log Book also records the start and end times for the burnout. Do all atmosphere furnaces and generators have flow scopes or flow meters for all gases?

The heat treater shall perform a minimum 3 hours purge prior to processing product not requiring ammonia as an addition. Reduction of 3 hours purge requires conclusive test data of the atmosphere to show no significant amount of residual ammonia is present in the furnace atmosphere. Log book, data logger, or other records shall document the actual purge time and that sufficient time has been allocated to remove ammonia from the furnace prior to processing parts in heat treat processes not specifying ammonia.

Flow scopes and meters All generators and furnaces have flow scopes for each gas line that is shall be periodically serviced per the heat treater's preventive maintenance connected, including endothermic gas, natural gas, air, nitrogen, and program.

Cleaning and proper re-assembly procedures shall be ammonia. The infrared temperature pyrometers are required at the exit end of continuous belt furnaces to monitor for under temperature parts. The o o temperature alarm shall be within 28 C 50 F of the furnace set point temperature.

Results shall be strip charted or continuously data logged. Infrared temperature pyrometers shall be calibrated annually at a minimum and certified. All sight glasses shall be cleaned per the preventive maintenance schedule. Is the quenching medium analyzed? X The heat treater shall periodically have the quenching medium analyzed for specific quenching characteristics, e. This review shall be documented.

The heat treater shall control the energy or power for each part. A signature monitor Does the heat treater control gives the energy unit voltage, kilowatt, etc. The heat treater shall have a coil management system. Coil refers to the heating coil and the quench plenum. The quench system shall be an automatic operation. No manual quenching is allowed unless specifically approved by the authorized customer representative. Quenching shall be automatically initiated and controlled.

The heat treater shall perform first piece set-up for each lot of parts. These air pockets will cause interrupted quenching at startIs there a procedure to purge up.

The Heat treater shall establish the time limit of the downtime when the air pockets from the this procedure is to be followed. Control PFMEA performed by designated Plans for each part are integrated into and qualified individuals - electronic electronic recipes. These are created and signoff of Team Feasibility evident for maintained by qualified individuals. Pass 4. AMP Quality Dept is notified if an apparent problem exists with parts or container, for disposition by the Quality Dept, but parts are placed on hold pending disposition.

List parameters that were verified in this audit in the spaces provided below. Pass Internal Proper recipe is integrated when part Hard copy WO shop traveler had number is entered into electronic Worp been compared to the furnace setup work order creation software during and settings.

Recipe does not have provision for adding additional steps to current WO. A hard copy of the WO is being used. Requirement: 1 Test Method: 4. Electronic signoff of process steps in WORP, as well as initialed on hard copy of the Work Order Pass Internal Most of the Control Plan, including inspection criteria, is integrated into electronic recipe in Worp software; a Generic Control Plan has also been created to address other aspects of control plans.

Internal Internal Requirement that certain critical No additional steps were performed. Retempering is not considered rework. Pass 1. Certification electronically signed by Quality Manager. Pass 2. Pass Shipping Requirements Were the parts properly identified? Customer PO. Pass Were the containers properly labeled?

Are parts packaged to minimize mixed parts for example, parts packed over height of container? AMP Router Tags were attached to customer bins. AMP Quality Dept is notified if an apparent problem exists with parts or container, for disposition by the Quality Dept. If necessary, parts are placed on hold pending disposition.

Control PFMEA performed by designated and qualified individuals - electronic Plans for each part are integrated into electronic recipes. These are created and signoff of Team Feasibility evident. Hard copy WO shop traveler was compared to the furnace setup and settings. Pass Internal Most of the Control Plan, including inspection criteria, is integrated into electronic recipe in Worp software; a Generic Control Plan has also been created to address other aspects of control plans.

If post-wash is performed, it is additional steps can only be authorized by allowed per AMP documentation the Quality Department. If the order was certified, did the certification accurately reflect the process performed? Rework of order requires Quality Department approval. Parts were evenly distributed in the AMP attempts to package outgoing material as closely to incoming packaging container and were not packed over the height of the container.

Pass Pass Pass Pass 4. AMP Quality Dept is notified if an apparent problem exists with parts or container, for disposition by the Quality Dept; parts are placed on hold pending disposition. Pass Question 4. A hard copy of the WO is being used on the shop floor.

If additional steps were performed, were they authorized? Additional washing step can be performed at Shift Leader's discretion, as allowed in AMP documentation. Pass No additional steps were performed. Pass Internal Requirement that certain critical No additional steps were performed. Data on Certification and data on WO match; data is electronically generated. Contact customer for rework approval. Pass Certification electronically signed by Quality Manager. Work Order Router Tag, identifying the parts within the container, were attached to Customer container.

AMP Router Tags were attached to customer containers. The customer may have additional requirements, e. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

Continuous furnace frequencies are per lot work order or as specified, whichever is more frequent. A program for furnace and generator burnout is required applies to carbon bearing atmospheres. The main task of technical committees is to prepare automotive standards and system requirements. Draft documents adopted by the technical comrnittees 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 acknowledge and thank the following individuals and their companies who have contributed time and effort to the development of this document. This 3rd edition is a collaborative work of OEM, Tier 1 suppliers, heat treat suppliers, and calibration companies that service the heat treat industry.

Below is a summary of the important changes in this 3'd edition. The format and layout of the Process Tables have been improved to facilitate the heat treat system assessment.

The requirement in the 3rct Edition allows the heat treater to choose one of the two following options: 5. Questions 1. Question 1. This question addresses re-processing procedures.

Question 3. This question addresses the proper height of the workload on a continuous belt fumace. These heat treat requirements are complementary to customer and product standards.

The HTSA can be used to assess an organization's ability to meet the requirements in this assessment, as welJ as customer, regulatory, and the organization's own requirements. The HTSA can also be used between an organization and its suppliers. In the HTSA, the word "shall" indicates a requirement for purposes of the self assessment. Failure to meet the requirements results in an assessment that is either "Not Satisfactory" or "Needs Immediate Action". The word "should" indicates a recommendation.

Where the term "such as" is used, any suggestions given are for guidance only. The HTSA, coupled with an intemationally recognized quality management system and applicable customer-specific requirements, defines the fundamental requirements for heat treat management systems. The HTSA is intended to provide a common approach to a heat treat management system for automotive production and service part organizations.

Assessment Process Ongoing assessments shall be conducted, ata minimum, annually, unless otherwise specified by the customer, to ensure continuous compliance with the HTSA. Each assessment shall include a review of the organization's systems using the HTSA.

Successive Job Audits Section 4. Dueto the vast differences in the various thermal processes currently available, it may be necessary to incorporate requirements across the provided process tables.

The assessor has the availability to employ requirements from multiple Process Tables if an element of the thermal process being assessed requires such. Assessor shall possess heat treating knowledge.

Assessor shall possess knowledge of and be familiar with the application of automotive quality core tools including statistical process control, measurement systems analysis, part approval, failure mode and effects analysis, and advanced quality planning.

These records shall be readily available for review by any customer requiring compliance to the requirements within this document. Documentation recovery shall meet TS or ISO requirements for process control and inspection records. Eight Process Tables have been developed and the appropriate table s is to be referenced during the assessment. These Process Tables contain requirements for: 1. Process and Test Equipment 2. Pyrometry 3. Process Monitor Frequencies 4. Quenchant and Solution Test Frequencies The Process Tables specify the tolerances of process parameters and the frequencies for checking process control parameters and parts.

The applicability is limited to the subject matter referenced. Complete the HTSA, determining the leve! Address each "Not Satisfactory" item and determine corrective action, including root cause analysis and implementation of the corresponding corrective action s. The corrective action s shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. Address each "Needs Immediate Action" item and determine corrective action s , including root cause analysis and implementation of the corresponding corrective action s.

Assessments shall be conducted annually unless otherwise specified by the customer. Facility Name: Name of the facility being assessed. One form shall be used for each facility. The facility may have several buildings or physical locations in the same general area. If there is a separate management team Quality Manager and Metallurgist or different management system, then these locations shall be considered as separate facilities. Address: The street address of the facility being assessed; P.

Box numbers may be given as additional information. Phone Number: The phone number of the facility. If there is no common phone number for the facility, the phone number ofthe Operations Manager or Quality Manager shall be used. Fax Number: The fax number of the facility. Number of Heat Treat Employees at this Facility: The number of employees, salaried and hourly, associated with the heat treat operation at this facility.

Such standards and specifications include, but are not limited to, those relevant documents 1. The referenced specifications organization shall have a process to ensure the current and available?

Timely review should be as soon as possible and shall nol exoeed tv. The organization shall idenlify who is responsible lor perfonning lhese tasks.

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These air pockets will cause interrupted quenching at start-up. Factors such as quench line diameter, length, geometry, etc.

The Heat treater shall establish the time limit of the downtime when this procedure is to be followed. The Customer may have additional requirements, e. When performing the job audit, the auditor shall verify heat treater is conforming to the Customer's requirements. Continuous furnace frequencies for item numbers A4.

When used for primary control of the carbon-bearing atmospheres, verification shall be daily. A six month calibration interval is allowed if multi-point calibration is utilized. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit as defined above. In absence of alarm system, sign-off every 2 hours and at the end of the cycle, or each cycle for processes under 2 hours satisfies this requirement. Continuous recording with alarm system set per limits in A2.

Generators shall be continuously monitored and recorded. Sign-off required for each shift for generators. An alarm system will satisfy the sign-off requirement.

Other systems, such as nitrogen-methanol systems, may either be continuously monitored and alarmed, or sign-off every 2 hours. Monitor atmosphere generation as applicable. Continuous recording with alarm system. Daily A3. Alarm systems if set per acceptable limits or continuous recording satisfy this requirement. Monitor load size, fixturing, Each batch or or loading rate as furnace load.

Monitor time in furnace, cycle time, or belt speed. Alarm systems if set per acceptable limits satisfy the sign-off requirement. Quench Level Continuous monitor with alarm or daily verification. Agitation Daily visual check, or monitor the agitation during the quenching operation with alarm systems set at acceptable limits.

Monitor each load. Alarm system is required. Fan speed or power. Cooling water temperature Monitor each load. Each basket for pushertype continuous furnaces where the loaded basket is quenched. Each load. Microstructure visual references shall be available. Daily per furnace unless Daily per furnace unless specified by Customer to specified by Customer to be checked with greater be checked with greater frequency, e.

Each batch or furnace load. Each lot or every 2 hours. Each lot or every 4 hours. Every six months complete replacement of the quench media and cleaning of the quench tank within six months satisfies this requirement. Every six months. Brine or Caustic Quench Media A5. Each shift. Cleaning Solution A5. Continuous furnace frequencies for item numbers B4. Not required for retort gas nitriding. Sign-off every 2 hours and at every 2 hours and at every 2 hours and at required for each the end of the cycle, the end of the cycle, the end of the cycle, shift for generators.

Monitor generator atmospheres, if applicable. Each furnace load or continuous recording with sign-off every 2 hours and at the end of the cycle, or each cycle for processes under 2 hours. Alarm systems satisfy the sign-off requirement. Continuous recording with alarms set per acceptable limits. Document with signoff each furnace load and every 4 hours minimum and after any change. Daily B3. Each batch or continuous recording with sign-off every 2 hours.

Continuous monitor with alarm or daily verification. Daily visual check, or monitor the agitation during the quenching Daily operation with alarm systems set at acceptable limits.

Daily per furnace unless specified by Customer to be checked with greater frequency, e. Suspended solids Every six months complete replacement of the quench media and cleaning of the quench tank within six months satisfies this requirement. Oil Quench Media B5. Continuous furnace frequencies for item numbers C4. Minimum and maximum temperature of the operating range shall be tested. The test temperature shall be within the operating range of the Qualified Work Zone.

Continuous recording with alarm system set per limits in C2. Temperature Continuous recording with alarm system set per acceptable limits. Continuous recording with alarm system set per acceptable limits. Nozzle pattern number and direction are to be defined, verified, and logged. Distribution pattern is to be defined, verified, and logged. Quench Media - Submerged Continuous monitor of level with alarm or daily verification.

Agitation Monitor the agitation during the quenching operation with alarm systems set at acceptable limits. Quench Media Process Parameters C3. Not applicable for furnaces where parts free fall into the quench. For other destructive testing For other destructive testing methods, daily per furnace methods, daily per furnace unless specified by Customer to unless specified by Customer to be checked with greater be checked with greater frequency, e. Concentration of cleaner Daily Daily Temperature of solution required if temperature is specified to be above ambient temperature.

In absence of process parameter alarms, also check process parameters at end of shift or lot whichever is the greater frequency. Check cycle time at start of production, every 8 hours, and after any process change. An energy monitor or signature monitor is required and shall be equipped with alarms set at acceptable limits. This requirement applies to each power supply not per coil. Monitor part temperature when specified.

Check at start of production, every 4 hours, and after any process change. Quench Media Level Continuous monitor with alarm or daily verification. Quench Pressure and Flow D3. In the absence of an alarm, the quench pressure and flow shall be checked at start of production run and every 8 hours. Each batch. Water Quench Media D5. Brine or Caustic Quench Media D5. Rust Preventive - Soluble Oil D5. Continuous furnace frequencies for item numbers E4. This is applicable when used in controlling carbon-bearing atmospheres.

Continuous Furnace Generators shall be continuously monitored and recorded. Other systems, such as nitrogen-methanol systems, may either be continuously monitored and alarmed, or signoff every 2 hours.

Monitor generator atmospheres. Daily Monitor time in furnace, cycle time, or belt speed. In absence of and recorded. Sign-off alarm system, sign-off alarm system, sign-off required for each shift every 2 hours and at the every 2 hours and at the for generators. An end of the cycle, or each end of the cycle, or each alarm system will cycle for processes cycle for processes satisfy the sign-off under 2 hours satisfies under 2 hours satisfies requirement. Cleaning Solution E5.

Vacuum monitoring devices shall be calibrated annually or verified annually against a calibrated master. Continuous recording with alarm system set per limits in F2. Daily, per qualified work zone chamber. Prior to production during APQP phase , the surface area of the parts shall be calculated and documented for each load configuration. Temperature Continuous recording with sign-off every 2 hours and at the end of the cycle, or each cycle for processes under 2 hours.

Quench Level Daily check or alarm system is required. Agitation Acceptable methods for checking agitation are using flow sensors, current sensors, or pressure differential sensors. Pressure in the quench cell Monitor each load. Fan speed or power Monitor each load. Cooling water temperature and flow rate Monitor each load. Temper Delay Time The maximum delay time between quenching Each batch or furnace load. Microstructure visual specification.

Oil Quenching F5. Continuous furnace frequencies for item numbers G4. In absence of alarm system, sign-off every 2 hours and at the end of the cycle or each cycle for processes under 2 hours satisfies this requirement.

Continuous recording with alarm system set per limits in G2. Daily G3. Not applicable for belt furnaces. One of the three options is required. Alarm system is required to ensure proper operation of the fans. If fan speed is variable, then verify fan speed every 8 hours, or after any change. Alternatively, using a Pre-mixed gas of Certified Composition satisfies this requirement.

Process temperature s shall be controlled with thermocouples in the load for each batch placed as practical to represent the extremes of the load minimum and maximum temperatures as evidenced by recording instruments. Monitor temperature control instrument s.

Continuous recording with alarm system set per limits per the control plan. In absence of alarm system, sign-off every 2 hours or each batch for processes under 2 hours satisfies this requirement. Daily Temperature of solution required if temperature Each shift. This process first austenitizes and then simultaneously quenches and forms a part. Quenching is achieved by direct contact with a die that is internally cooled with a suitable medium. The die is used in conjunction with a high tonnage press and relatively short heat treat cycles are used.

All requirements given below are subordinate to customer specific requirements. Continuous recording with alarm system set per limits in I2. In absence of alarm system, sign-off every 2 hours satisfies this requirement. In absence of alarm system, sign-off every 2 hours for each chamber satisfies this requirement. An alarm system will satisfy the signoff requirement. Monitor primary furnace atmosphere control s , as applicable Continuous recording with alarm system.

For each chamber, continuous recording with alarm system. Monitor time in furnace. System monitoring of time in furnace ex. Robot, PLC, etc. Alarm for times outside of process window.

For each chamber, system monitoring of time in furnace ex. Roller speed. Press cycle parameter e. There shall be an alarm for conditions outside of process window. Quench Process Parameters I3. Alarm for temperature control systems are required. Monitoring of die cooling system flow. Alarm for flow control systems are required. Daily per furnace chamber. May rotate Daily per furnace.

Daily per furnace. May rotate chambers but Daily per furnace. At start up per cavity and every 4 hours At start up per At start up per cavity minimum per cavity. Cooling media contamination. Per maintenance and equipment plan. Copyright AIAG. Home CQI-9 4th Edition. Supersystem-4th 40 2 12MB Read more. English File 4th edition 2 26MB Read more. Structral Analysis - 4th Edition. Interchange 4th Intr-SB www. Your name. Close Submit.

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