CQI-15 WELDING SYSTEM ASSESSMENT PDF

Bajar Enter N if this facility does not weld any components for other companies. They shall address all process steps from part receipt to part shipment and identify all equipment used and all essential welding process parameters as defined by the relevant individual process tables or non-essential as agreed upon between supplier and customer. The welding organization shall contact the customer when clarification of process changes is required. CQI Welding System Assessments Number of years in business: All welding employees, including backup and temporary employees, shall be trained. System Assessment Instructions for completing the Job Audit The organization is to complete a minimum of one welding part job audit during each assessment. AIAG Projects Volunteer committees focus on business processes or supporting technologies and methodologies.

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Publication of tbe documents requires approval by tbe Quality Steering Committee The Quality Steering Conunittee would like to acknowledge and tbank the following individuals and their companies wbo have contributed time and effort to the development ofthis document. These welding requirements are complementary to customer and product standards. Successive Job Audits Section 6. Assessor shall possess welding knowledge.

Evidence shall include a minimum of 5 years experience in welding or a combination of formal education in welding and welding experience totaling a minimum of 5 years 3. These records shall be readily available for review by any customer requiring compliance to the requirements within this documen t.

There are other reference materials that contain more infonnation , however, the list is not meant to be inclusive. The applicability is limited to the subject matter referenced [:ff..? The corrective action s shall be completed within 90 days. Tbe corrective action s shall be completed within 90 days. Records oftbe corrective action , including verification , shall be maintained 2. Address: The street address ofthe facility being assessed; P.

Enter "N" ifthis facility does not weld any components for other compames Date of Assessmen t: Enter the date s ofthe assessmen t. This information determines the appropriate Process Table that shall be used during the assessment. If customer quality certification is given , then the year of the last assessment by the customer shall also be given.

Sections 1 - 5 Sections 1 - 5 contain questions and the requirements and guidance for each question. The Sections are? When the Process Tables are pertinent to the Question, the assessor shall assess the weld organization compliance to the specified section s in the Process Tables.

Section 1 - Ma nageme nt Responsibility To ensure readily available expertise. The organizalion shall provide employee Iraining lor all we lding operalions specific 10 lheir job funclion. A feasibility study shall be performed and internally approved for each part.

Afler the part approval process is approved by the customer , no process changes perform advanced quality are allowed unless approved by the cuslomer.

The planning? The organization shall have a process 10 ensure referenced specil? The organization shall identify who is responsible for performing Ihese lasks.

The welding organization shall have written process specificalions lor al! Capability study techniques shatl inctudc boundary sample conditions as defined by th e controt plan thal are robusl and meel att customer requirements. Example , any combinalion 01 toterances as delined by Process Tables The analysts 01 products or processes over lime can yietd for defect prevention efforts. The Does Ihe wetding organization organization shalt have a syslem 10 coltecl , analyze. Management shalt review the wetd process control systems.

The managemenl review shatt include efforts 10 delecl out-of-control condilions or atarm conditions. The process of reviewing the controt syslem shall be documenled and recorded in the conlrol plan 1. The quatily managemenl system shatl inctude a process Does Ihe Qualily Department for documenling. Ishall be comple! There shall be procedures or work instructions available 10 welding personnel covering the welding process.

These procedures or work instructions shall be accessible 10 shop floor personnel The organization sl1 all have a documented preventive mainlenance program for process equipment as identified by the Process Tables. The program shall be a closedloop process thal tracks maintenance efforts from requesl 10 completion 10 assessmenl of effectiveness.

Equipmenl operators shall have Ihe opporlunily 10 report problems , and problems shall also be handled in a closed-Ioop manner Company dala , e. Is mainlenance data being ulilized 10 form a p redictive mainlenance program?

The qualily management system shall include a documented process for reprocessing and repair that shall in c! Any reprocessing activity sha l1 require a new processing control sheet issued by qualffied technical repair? The facility shall have a delailed process in place 10 resolve receiving discrepancies. This process refers 10 receiving an shipping the parts in and out 01 the welding department 2. Cuslomer producl shall be c! Non-welded , in-process. A non-conforming hold produclion syslem?

After emptying and before re-using conlainers , containers shall be inspected 10 ensure that all parts and inappropriale material have been removed. The source 01 inappropriate material sha Jl be identified and add ressed. Examples include part load sequence and documenled and conlrolled? Work instructions specifically addressing potential types of eQuipment emergencies and fail ures shall be accessible 10 and understood by equipmenl operalors. These instructions shall address containmenUreaction plans related 10 a!

Evidence shall exist showing disposilion and traceability of affected produc t. A housekeeping policy shall be clearly defined and and working condilions execvted. The facility shall be reviewed for condilions that conducive 10 conlrol and are detrimental 1 0 quality processing such as e parl5 improved quality?

On , and adequate lighling The power supply should be adeq uate for Ihe manufacturing process with consideralion not limited 10 output energy , duly cycle , oooling , now rates and grounding 3. Has a preventalive maintenance program been eslab Ji shed and documented? Refer 10 Seclion 1. Refer to th e. This shall be ca ptured in tools such as th e se!

The welding operation shal! These checks shall be documented. Are Ihe. Are the lin9 componen ts designed lor Ihe weld ing process? Weld faults audible , visib le and line shul down At weld cycle interrupl , part must nol be removed or passed until dlsposltioned by appropriale personnel Calibra tion 01 metcrs and system conlrols. Are In.

Process and Final Tests performed at established fre quencies? Process cieos netmEt apbaltmshmeedhmqhse hcao 11be mombred per frequencies eslablished in the conlrol plan. Is there documented evidence that reaction ptans are fotlowed?

Each process should be acted on according 10 th e level 01 change. 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 , especia l1 y ifthe fastener manufacturer does not identify the end customer auto manufacturer , tier one , etc. Parts sha l1 be taken from the shipping area at the dock or the end of the welding operation. The part checked sha l1 represent a major weld operation such as an individual operation , cell , or assembly line.

In subsequent welding system assessments , different parts and welding processes sha l1 be checked The specific welding processing parameters applies to 6. Has the logic been established 10 effectively identify and address process or equipmenl faults? Are over rides or resets maintained? Are weld faults aUdible , visible and does the line shul down? If the weld cycle is interrupled , IS the parl conlrolled or contained until dispositioned by appropriale personnel?

Are Ihe melers and feed back conlrols calibraled per eslablished frequencies? If applicable , is Ihere an inler- ocking of the previous operation and has the quality of parts been verified? Are highllow limi!

Have process variables been defined and developed by dala and shown 10 be stalislically capable? Are Ihere documented welding procedures for each weld localion and each process variable?

Is there a documented change over procedure filler materia l , fixtures? Is there a documented start. Are process control paramelers monitored at established frequencies?

How does the organization handle changes 10 process con trol parameters after initial customer approval and how do yau notify your cusl omer? Are In -Process and Final Tests performed al established frequencies?

Are weld qualily requirements clearly defined per customer specifications? Pa r1 s must meet each requiremen t. Ust requirements below and validate E. Das hes be low indicate " not applicab le". The customer may have add ition al requirements , e.

Dashes below indicate "nol applicable". X indicates an essenti al variable which sha ll be documented and controlled.

Processes can be used bolh with and withoul filler melal x2. The custo mer may have add itiona l requirements , e. Eleclrode geomelry Indu ction coil geometry Secondary loop electrical conduclors cables , leaf shunts , elc.

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AIAG CQI-15

Supplier Quality Assurance Supplier Quality Assurance Preface We strive to continually improve our process performance by meeting quality objectives. The welding organization shall contact the customer when clarification of process changes is required. The job audit of one part, one weld process, is not sufficient to use as a basis to complete the other sections of the complete WSA. Job Audit Process Requirement Tables. The applicability is limited to the subject matter referenced. Needs Immediate Action requires immediate containment of suspect product. Search for Training Course Keyword: Place a checkmark to designate all welding process es performed at this facility.

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AIAG CQI 15 PDF

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 federal law subject to criminal and civil penalties. This individual shall be one of the following: Degreed Welding Engineer, or equivalent science degree, Certified Welding Inspector from approved internationally recognized body, or person agreed upon between customer and supplier. This person shall be a full-time employee and the position shall be reflected in the organization chart.

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AIAG CQI-15

Publication of tbe documents requires approval by tbe Quality Steering Committee The Quality Steering Conunittee would like to acknowledge and tbank the following individuals and their companies wbo have contributed time and effort to the development ofthis document. These welding requirements are complementary to customer and product standards. Successive Job Audits Section 6. Assessor shall possess welding knowledge. Evidence shall include a minimum of 5 years experience in welding or a combination of formal education in welding and welding experience totaling a minimum of 5 years 3. These records shall be readily available for review by any customer requiring compliance to the requirements within this documen t.

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CQI-15 WELDING SYSTEM ASSESSMENT PDF

Karamar Are procedures adequate to prevent movement of nonconforming product into the production system? If an automotive manufacturer s part is weldiny available or identifiable, then parts from other customers requiring compliance with this document shall be used for the assessment. The organization shall have a system to collect, analyze, and react to product or essential process data over time. Each process path includes all combinations of equipment that are integrated in the performance of a welding process, welidng. The facility shall be reviewed for conditions that are detrimental cql quality processing such as loose parts on floor, contaminants, oil, inadequate plant lighting, fumes, etc. Nexteer Automotive — 3.

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