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1、CQICQI-1515SpecialSpecial Process:Process:WeldingWelding SystemSystem AssessmentAssessmentVersion 2 Issued 10/2019AIAG CQI-15 Special Process:Welding System AssessmentCompany Name:CurrentStatusREDJob Audit SummaryStreet Address:GMAW OverallNot CompletedCountry/City/State/ZIP Code:Weld System%Complia
2、nce33.33%GMAW CTQ0 RED CTQ ItemsSite Code:LBW OverallNot CompletedParent Code:Job Audit%ComplianceNotCompletedLBW CTQ0 RED CTQ ItemsCurrent Quality Certification(s):Drawn Arc OverallNot CompletedDate of This Assessment:January 18,2021Overall Total of WSAand Job Audits33.33%Drawn Arc CTQ0 RED CTQ Ite
3、msDate of Initial Assessment:Resistance OverallNot CompletedDate of Re-Assessment(if necessary):Resistance CTQ0 RED CTQ ItemsNumber of Welding Employees at this Facility:Friction OverallNot CompletedCaptive Weld Organization(Y/N):Friction CTQ0 RED CTQ ItemsInduction OverallNot CompletedReview Member
4、sTitleEmail AddressPhoneInduction CTQ0 RED CTQ ItemsFastener Projection Not CompletedFastener Projection CTQ0 RED CTQ ItemsMIAB OverallNot CompletedMIAB CTQ0 RED CTQ ItemsCTQ=Critical to QualityHigher is BetterSite Responsible PersonTitleEmail AddressPhoneSupplier ContactsTitleEmail AddressPhoneWeld
5、 Classifications:Ship To LocationsTier Level Contact NameContact eMailWelding Processes Used:Welding Specifications Used:Commodity:ChassisPart Number(s)Assessed:Vehicle/ProgramProduct InformationOverall Summary Comments:LEGENDRedAny RED ElementDoes NOT meet the requirements,needs immediate action.Pr
6、ocess review indicates that there is a risk of non-conforming product.Yellow100%GREEN-0-REDDoes NOT meet the requirements,containment is in place.Process review indicates that there is sufficient containment of non-conforming product.Green100%GREENMeets all requirementsSUMMARY of RESPONSESWelding Sy
7、stem AssessmentSection%Compliance ofRated ElementsREDYELLOWGREENPossibleElementsSection 1Weld System Process Assessment(SPS Assessment)33.33%1117Section 2DocumentationNot Completed00018Section 3Preplanning/Quality DocumentationNot Completed00026Section 4Production Monitoring/DocumentationNot Complet
8、ed00022Section 5Rework or Scrap Procedures and ReportsNot Completed0005%of Items Completed3.85%Section 1-5 Total33.33%111WELDING JOB PROCESSESSection%Compliance ofRated ElementsREDYELLOWGREENPossibleElementsGMAW Overall1.PART PRINTNot Completed0006Not Completed2.CONTROL PLANNot Completed00011GMAW Cr
9、itical to Quality3.DESTRUCTIVE&NONDESTRUCTIVE TESTING DATANot Completed00030 RED CTQ Items4.WELD QUALITY INSPECTION&REPORTSNot Completed00010%of Items Completed5.REWORK PROCEDURE&REPORTSNot Completed00090.00%6.PARAMETER DOCUMENTATIONNot Completed000207.MAINTENANCE RECORDSNot Completed00078.SUSTAINAB
10、ILITYNot Completed00029.EQUIPMENT&ROBOTIC PROCESSING REQUIREMENTSNot Completed0005LBW Overall1.PART PRINTNot Completed0006Not Completed2.CONTROL PLANNot Completed00013LBW Critical to Quality3.DESTRUCTIVE&NONDESTRUCTIVE TESTING DATANot Completed00030 RED CTQ Items4.WELD QUALITY INSPECTION&REPORTSNot
11、Completed00010%of Items Completed5.REWORK PROCEDURE&REPORTSNot Completed00090.00%6.PARAMETER DOCUMENTATIONNot Completed000407.MAINTENANCE RECORDSNot Completed00098.SUSTAINABILITYNot Completed00029.EQUIPMENT&ROBOTIC PROCESSING REQUIREMENTSNot Completed0002Drawn Arc Overall1.PART PRINTNot Completed000
12、5Not Completed2.CONTROL PLANNot Completed00010Drawn Arc Critical to Quality3.DESTRUCTIVE&NONDESTRUCTIVE TESTING DATANot Completed00030 RED CTQ Items4.WELD QUALITY INSPECTION&REPORTSNot Completed0008%of Items Completed5.REWORK PROCEDURE&REPORTSNot Completed00090.00%6.PARAMETER DOCUMENTATIONNot Comple
13、ted000277.MAINTENANCE RECORDSNot Completed00088.SUSTAINABILITYNot Completed00039.EQUIPMENT&ROBOTIC PROCESSING REQUIREMENTSNot Completed0001Resistance Overall1.PART PRINTNot Completed0005Not Completed2.CONTROL PLANNot Completed00012Resistance Critical to Quality3.DESTRUCTIVE&NONDESTRUCTIVE TESTING DA
14、TANot Completed00030 RED CTQ Items4.WELD QUALITY INSPECTION&REPORTSNot Completed0009%of Items Completed5.REWORK PROCEDURE&REPORTSNot Completed00090.00%6.PARAMETER DOCUMENTATIONNot Completed000277.MAINTENANCE RECORDSNot Completed00098.SUSTAINABILITYNot Completed00039.EQUIPMENT&ROBOTIC PROCESSING REQU
15、IREMENTSNot Completed0001Friction Overall1.PART PRINTNot Completed0004Not Completed2.CONTROL PLANNot Completed00017Friction Critical to Quality3.DESTRUCTIVE&NONDESTRUCTIVE TESTING DATANot Completed00030 RED CTQ Items4.WELD QUALITY INSPECTION&REPORTSNot Completed00010%of Items Completed5.PARAMETER DO
16、CUMENTATIONNot Completed000280.00%6.MAINTENANCE RECORDSNot Completed00067.SUSTAINABILITYNot Completed00028.EQUIPMENT&ROBOTIC PROCESSING REQUIREMENTS Not Completed0001Induction Overall1.PART PRINTNot Completed0004Not Completed2.CONTROL PLANNot Completed00013Induction Critical to Quality3.DESTRUCTIVE&
17、NONDESTRUCTIVE TESTING DATANot Completed00030 RED CTQ Items4.WELD QUALITY INSPECTION&REPORTSNot Completed00010%of Items Completed5.PARAMETER DOCUMENTATIONNot Completed000170.00%6.MAINTENANCE RECORDSNot Completed00027.SUSTAINABILITYNot Completed00018.EQUIPMENT&ROBOTIC PROCESSING REQUIREMENTSNot Compl
18、eted0001Fastener Projection Overall1.PART PRINTNot Completed0004Not Completed2.CONTROL PLANNot Completed00010Fastener Projection Critical to Quality3.DESTRUCTIVE&NONDESTRUCTIVE TESTING DATANot Completed00030 RED CTQ Items4.WELD QUALITY INSPECTION&REPORTSNot Completed00014%of Items Completed5.REWORK
19、PROCEDURE&REPORTSNot Completed00090.00%6.PARAMETER DOCUMENTATIONNot Completed000297.MAINTENANCE RECORDSNot Completed00088.SUSTAINABILITYNot Completed00029.EQUIPMENT&ROBOTIC PROCESSING REQUIREMENTSNot Completed0001MIAB Overall1.PART PRINTNot Completed0004Not Completed2.CONTROL PLANNot Completed00016M
20、IAB Critical to Quality3.DESTRUCTIVE&NONDESTRUCTIVE TESTING DATANot Completed00030 RED CTQ Items4.WELD QUALITY INSPECTION&REPORTSNot Completed0009%of Items Completed5.PARAMETER DOCUMENTATIONNot Completed000180.00%6.MAINTENANCE RECORDSNot Completed00057.SUSTAINABILITYNot Completed00028.EQUIPMENT&ROBO
21、TIC PROCESSING REQUIREMENTSNot Completed0001Job Audit TotalNot Completed000Overall Total33.33%111CQICQI-1515SpecialSpecial Process:Process:WeldingWelding SystemSystem AssessmentAssessmentVersion 2 Issued 10/2019Weld System AssessmentAssessor00Date18-Jan-21(Name-Company)(Name(Name -Location)Location)
22、ItemNo.QuestionRequirements and Guidance1/0/1900InitialRating(R/Y/G)Evidence/Gap Identified1/18/2021CurrentStatus(R/Y/G)Follow up CommentsSection 1-Weld System Process Assessment1.1Are internal assessments being completed on anannual basis,at a minimum,using AIAG WeldingSystem Assessment(WSA)?The or
23、ganization shall conduct internal assessments on an annual basis,at a minimum,unless otherwise specifiedby the customer,using the AIAG WSA.Concerns shall be addressed in a timely manner.Yellow=START HEREYellow1.2Is there a dedicated and qualified technical weldingperson on-site?To ensure readily ava
24、ilable expertise,there shall be a dedicated,qualified and full time welding person on site.Thisindividual shall be one of the following:1.Degreed Welding Engineer,or equivalent science degree.2.Certified Welding Inspector from approved internationally recognized organization.3.A minimum of 5 years e
25、xperience in welding operations or a combination of a minimum of 5 years of formalmetallurgical education and welding experience.4.A qualified person agreed upon between customer and supplier with documentation approval.GreenGreen1.3Are the facilities sufficient for the welding operation?Facilities:
26、could include but is not limited to,capabilities such as safety,environmental regulations/practices,air(sizing,filtering and cleanliness),gas mixing system(equipment and sizing),ventilation,and adequate lighting.Utilities:sufficient incoming power(balance and loading)and water.RedRed1.4Are the power
27、 supplies sufficiently sized and protected?The power supply should be adequate for the manufacturing process with consideration not limited to output energy,duty cycle,cooling,flow rates and grounding.Power supply grounding per OEM and regulatory specifications.Surge protection and power fluctuation
28、/regulation.1.5Is the handling,storage and packaging adequate topreserve product quality?The welders loading system,in-process handling,and shipping process shall be assessed for risk of part damageor other quality concerns.Other practices such as stacking of overloaded containers can also increase
29、the risk ofpart damage.1.6Are plant cleanliness,housekeeping,environmentaland working conditions conducive to quality?Plant cleanliness,housekeeping,environmental,and working conditions shall be conducive to quality.The weldingorganization shall evaluate such conditions and their effect on quality.A
30、 housekeeping policy shall be clearlydefined and executed.The facility shall be reviewed for conditions that are detrimental to quality processing such asloose parts on floor,contaminants,oil,inadequate plant lighting,fumes,etc.1.7Is there a preventive maintenance program specific tothe welding proc
31、ess?Is the maintenance data beingutilized to verify the effectiveness?The organization shall have a documented preventive maintenance program for weld process equipment.Theprogram shall track maintenance schedules.Maintenance data shall be collected and analyzed as part of apreventive maintenance pr
32、ogram.Section 2-Documentation2.1Is there a responsibility matrix to ensure that all keywelding management and supervisory functions areperformed by qualified personnel?The matrix shall identify both primary and secondary(backup)personnel for the key functions(as defined by theorganization).This matr
33、ix shall be readily available to management and customer at all times.2.2Does the welding organization perform advancedquality planning?A manufacturing feasibility study shall be performed and internally approved for each part.Similar parts can begrouped into part families for this effort as defined
34、 by the organization.2.3Is management reviewing the weld control system at afrequency determined by the control plan?Management shall review the weld process control systems along with reviewing the efforts to detect out-of-controlconditions or alarm conditions.The process of reviewing the control s
35、ystem shall be documented and recorded inthe process control plan.2.4Are welding DFMEAs and PFMEAs up to datereflecting the current weld processing?The organization shall incorporate the use of a documented Failure Mode and Effects Analysis(FMEA)procedureand ensure the FMEAs are updated to reflect c
36、urrent part quality status.The PFMEA shall be written in conjunctionwith the DFMEA.2.5Are all OEM and referenced welding standards currentand available?For example:SAE,ASTM,ASME,AWS,ISO.The organization shall have all current customer specific welding standards and specifications.The organizationsha
37、ll identify who is responsible for maintaining,distributing,and implementing the standards/specifications.2.6Does the Quality Department review,address,anddocument customer and internal concerns?The quality management system shall include a process for documenting,reviewing,and addressing customer w
38、eldconcerns and any other concerns internal to the organization.A disciplined problem solving approach shall be usedfor internal concerns and concerns identified by the customer.2.7How does the organization document and respond toquality spills,nonconformance,customer concerns?Reaction plans are to
39、be followed per the process control plan and PFMEA or,in the case of newly identified issuesPFMEA and control plan shall be updated to reflect the new failure mode and reaction steps taken.2.8Are procedures adequate to prevent movement of non-conforming product into the production system?The control
40、 of suspect welded product is required to prevent shipment of non-conforming product.Procedures shallexist addressing proper disposition,product identification,and tracking of material flow in and out of the hold area.Anon-conforming hold area shall be clearly designated to maintain segregation of s
41、uch material.2.9Does the Quality Manager or designee authorize thedisposition of material from a quarantine status?The Quality Manager or designee authorizes the disposition of the quarantined material with supportingdocumentation.2.10Have the necessary replacement parts and processconsumables been
42、identified and made readilyavailable?The welding organization shall develop and maintain a critical spare parts list and shall ensure the availability ofsuch parts to minimize production disruptions.Critical parts may include high frequency occurrence or long leadtime items.2.11Does the organization
43、 use only qualified welders(personnel)and how is welder certification maintained?All welding employees,including backup and temporary,shall be trained specific to their job function.Documentedevidence shall be maintained showing the employees were trained;the evidence shall include an assessment of
44、theeffectiveness of training,shall prove knowledge of the customers specific requirements and internal standards.Employee certification,such as for a manual welder,shall be documented.Required qualification maintenance.If the employee has a qualification lapse in the specific operation in a 6 montht
45、ime frame,the welder shall be requalified to that operation.Based on the welders quality performance,it shall beestablished when retraining and requalification of the individual shall be performed.2.12Are there procedures and work instructions available?There shall be procedures and work instruction
46、s available for welding personnel covering the welding process.These procedures and work instructions shall include methods of addressing potential emergencies such as powerfailure,start-up,shut-down,product segregation(See 2.8),product inspection,safety,house-keeping,and generaloperating procedures
47、.These procedures or work instructions shall be accessible and used to train shop floorpersonnel.2.13Are there documented weld procedure specifications(WPS)?The welding organization shall have controlled written process specifications for all active processes and repairprocedures which identify all
48、steps of the process including operating parameters as defined by the relevant processtables.The parameters shall be defined with operating tolerances.2.14Are the tooling components designed for the weldingprocess?Fixturing/tooling was developed considering movement,reach,accessibility,tool center p
49、oint,maintenance,andergonomics(manual,automatic,and robotics)to maintain weld process angles.2.15Is there a record of the design and set-up of the fixture?Supplier shall have documentation of the fixture design,that are stored properly and accessible.Properidentification and revision level on the fi
50、xture or related to the fixture.Documented fixture set-up(i.e.,clamps,pins,locating devices,and shim packs).2.16Is the weld cell set-up procedure compliant to the workinstructions?Set-up shall be verified to be in compliance to the documented work instructions.(i.e.,equipment parameters,clamping seq