Special Process: Heat Treat System Assessment

1 CQI-9 Special process : Heat Treat System AssessmentFourth Edition, June 2020 Date of Assessment :Date of Previous Assessment :Internal (Captive) Heat Treater (Y/N):Commercial Heat Treater (Y/N): YesNoYesNoYesYesYesNoYesYesAging OnlyNoNoNoNoNoYesNoName:Phone:Jason :Phone:Brad process : Heat Treat System Assessment Facility Name: State Heat Treating CompanyAmerican Systems RegistrarPlant ManagerPresident/OwnerAluminum Heat TreatmentProcess Table I Hot StampingCurrent Quality Certification(s): ISO-9001:2015 Company:Personnel Table ECarbon RestorationAnnealingNYProcess Table C Ion NitridingAuditors/Assessors:Number of "Fail" Findings in the Job Audit(s): 0 Date of Re- Assessment (if necessary): 01/23/2022 Number of "Not Satisfactory" Findings: 0 Number of "Needs Immediate Action" Findings: (Gas)Ferritic-Nitrocarburizing (Gas or Salt)Sinter HardeningProcess Table HNeutral Hardening (Quench and Temper)NormalizingAustempering / MartemperingStress-RelievingAddress: 520 32nd St SE, Grand Rapids, MI 49548 Phone Number: Table B process Table GProcess Table A process Table D CarburizingInduction Heat TreatingType(s) of Thermal Processing at this Facility:Precipitation Hardening / AgingLow Pressure Processing ( carburizing / Carbonitriding / Neutral Hardening)TemperingProcess Table F10/29/2021 Fax Number: 2020 Copyright AIAGCQI-9 Special process .

2 Heat Treat System AssessmentFourth Edition, June 2020 EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionJD-009 (Quality Technician) require education and five years of heat Treat Organization ChartxJD-009 (Quality Technician) require education and five years of heat Treat (Quality Technician) require education and five years of heat Treat EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionSee WI-7-001 Product process and required fields are utilized in the ERP part receives its own process with all changes and modifications recorded in the Part Master new part is reviewed and processed per a family FMEA and control EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionFMEAs are done for families of parts and are done for families of parts and processes and mimic the 1 - Management Responsibility and Quality PlanningPlease describe Objective Evidence for each RequirementIs there a dedicated and qualified heat Treat person on-site?

3 To ensure readily available expertise the following requirements shall be shall be a dedicated and qualified full-time heat Treat person on position shall be reflected in the organization job description shall exist identifying the qualifications for the positions including appropriate metallurgical and heat Treat knowledge for the shall be available regarding the qualifications with a minimum of 5 years experience in heat Treat operations or as a combination of a minimum of 5 years of formal metallurgical education and heat Treat the heat treater perform advanced quality planning?The organization shall incorporate a documented advance quality planning process . A structured System for such process with the APQP elements is recommended, samples are available in the AIAG APQP manual or other equivalent national automotive industry standards. Similar parts can be grouped into part families for this effort as defined by the shall be documented advance quality planning procedure :Feasibility studies shall be performed and internally approved for each part or group of similar shall be a documented System for process changes with approval by the :Are heat Treat FMEAs up to date and reflecting current processing?

4 Failure Mode and Effects Analysis (FMEA) for processes (PFMEA) is mandatory for the prevention of product/ process failure modes and final product concerns. Examples of appropriate methods and standards include SAE J1739, AIAG & VDA FMEA shall be a documented Failure Mode and Effects Analysis (FMEA) procedure with the present FMEAs updated and reflecting the current part quality shall address all process steps from part receipt to part shipment and all the key heat Treat process parameters as defined by the Copyright AIAGCQI-9 Special process : Heat Treat System AssessmentFourth Edition, June 2020 Each plan is reviewed yearly with all changes recorded on the FMEA located in their respective parts plan is reviewed yearly with all changes recorded on the FMEA located in their respective parts EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionControl Plans are done for families of parts and Plan are done for families of parts and processes and mimic the plan is reviewed yearly with all changes recorded on the Control Plan located in their respective parts plan is reviewed yearly with all changes recorded on the Control Plan located in their respective parts standard work instructions define the sample sizes and frequencies per the applicable process EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionAll specifications used for any given process will be indicated on the control plan and will be updated along with the

5 Review of the plan at its yearly customer specifications will be reviewed at receipt and will not be controlled. Print revisions, if provided, will be recorded on our internal process and verified at order entry. All specifications are purchased as needed and electronically filed in a rational hierarchical any changes be needed, the ERP will be updated to reflect any requested Special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the cross-functional team shall be used in the development of the FMEA and shall be consistent with all associated documentation such as Control Plans, work instructions and shop : Are heat Treat process control plans up to date and reflecting current processing?Reference automotive industry Control Plan guidelines. The Control Plan may be specific for each part or part family or it can be process specific and written for each process .

6 In any case it describes required controls and actions for each process step as well as periodic requirements to assure process is in control. RequirementsThe organization shall incorporate the use of a documented Control Plan reflecting the current Plans shall address all process steps from part receipt to part shipment and identify all equipment used and all key heat Treat process parameters as defined by the cross-functional team shall be used in the development of the Control Plan and shall be consistent with all associated documentation such as FMEAs, work instructions and shop Special characteristics as defined by the organization or its customers shall be identified, defined, and addressed in the applicable control plan. Sample sizes and frequencies for evaluation of process and product characteristics shall be addressed and shall be consistent with the minimum requirements listed in the applicable process :Are all heat Treat related and referenced specifications current and available?

7 For example: Material standards, SAE, AIAG, ASTM, General Motors, Ford, and document control System is pertinent for the handling and internal distribution of received customer specifications and to keep up to date with national or global standards related or close to heat Treat processes. The procedure shall include a 2-week distribution limit for cascading newly received and reviewed organization shall have all related heat Treat and customer referenced standards and specifications available for use, like but not limited to SAE, AIAG, ASTM, ISO, EN, JIS, General Motors, Ford, and organization shall have a procedure and process to ensure the timely review, distribution and implementation of all customer and industry engineering standards/specifications and changes based on customer-required Copyright AIAGCQI-9 Special process : Heat Treat System AssessmentFourth Edition, June 2020 EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionQuality Technician is responsible for establishing process written process specs and BOM is listed in ERP Master Parts File.

8 And all revisions are recorded in the change Variables are reviewed annually and listed on the control panel next to each levels of standard work instructions exist in the QMS to define the process written process specs and BOM is listed in ERP Master Parts File; and all revisions are recorded in the change written process specs and BOM is listed in ERP Master Parts File; and all revisions are recorded in the change EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionModifications or rebuilds that affect atmosphere are subject to new capabilitiy studies to validate both the process variables and also the process results tell us if we are in control of each process based on the specifcations required from each is standard work that defines the handling of non-conforming material. P-8-002 Control of Nonconforming ProductxHas the heat Treat process been validated initially and after process equipment has been relocated, or had a major rebuild or modification?

9 All process specification changes shall be documented to include the date the process specification change was implemented and the person(s) approving the there a documented System to create process specifications for all active processes?A documented System for creating process specifications is necessary for operating the heat Treat process within the desired, requested process parameters to reach the final product specifications. Examples of process parameters include process temperatures, cycle times, load rates, atmosphere or gas flow settings, belt speeds, quench agitation speeds, demonstrate each heat Treat process is capable of yielding acceptable product, the organization shall perform process validation as part of the initial validation of each process , after relocation of any process equipment or heat Treat location change, and after a major rebuild of any equipment.

10 Each process line may include a combination of equipment that is integrated in the performance of a heat Treat process , hardening, quenching and tempering. (Heat Treat process validation consists of robust heat Treat equipment, rigorous process controlling and monitoring requirements and calibrations, appropriate test equipment calibrations, and strategic product sampling techniques.)The organization shall define what constitutes a major rebuild or modification that may impact product :An action plan shall exist if process control parameters or any of the product characteristics fall outside of the control tolerance limits or the heat treater does not conform to the respective process validation shall be performed on full production load, or production run, with production intended fixturing and load :All process specification changes shall be reviewed to the extent necessary to ensure continued conformity with customer requirements for process specifications shall be available in the form of work instructions, job card, computer-based recipes, or other similar shall have operating tolerances as defined by the organization in order to maintain process heat treater shall have written process specifications for all active processes and identify all steps of the process including relevant process shall be defined to a responsible person (see ) for establishing process specification for the heat treatment of the products with the available Copyright AIAGCQI-9 Special process : Heat Treat System AssessmentFourth Edition, June 2020 We perform capability studies on each furnace line for each process family that is associated with that line.