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1、CQI-9Special Process:Heat Treat System AssessmentVersion 2,Issue 8/07Special Process:Heat Treat System Assessment 特特殊殊过过程程:热热处处理理过过程程评评审审Notes from Larry HongFacility Name:工工厂厂名名称称Address:地地址址Phone Number:电电话话Type(s)of Thermal Processing at this Facility:热热处处理理类类型型Fax Number:传传真真Process Table A-Ferr
2、ous工工艺艺表表A铁铁基基金金属属Carburizing渗渗碳碳Number of Heat Treat Employees at this Facility:Carbonitriding碳碳氮氮共共渗渗Austempering 实际上就是等温淬火，最终得到贝氏体。Martempering 实际上就是分级淬火。需要后续常规回火。中性淬火，是加热时，炉内碳势与原材料含碳量相当，避免脱碳。本本部部门门热热处处理理员员工工数数量量：Carbon Correction修修复复渗渗碳碳Captive Heat Treater(Y/N):Neutral Hardening中中性性硬硬化化公公司司内内部部
3、有有热热处处理理过过程程吗吗Quench&Temper淬淬火火回回火火Commercial Heat Treater(Y/N):Austempering/Martempering奥奥氏氏体体回回火火/马马氏氏体体回回火火有有外外包包的的热热处处理理过过程程吗吗Tempering回回火火Date of Assessment:评评审审日日期期Precipitation Hardening/Aging沉沉淀淀强强化化/时时效效处处理理脱溶硬化处理适用于铝合金，锰合金，钛合金，镍合金的硬化处理。本人知之甚微。Date of Previous Assessment:先先前前评评审审日日期期Process
4、 Table B-Ferrous工工艺艺表表B铁铁基基金金属属Nitriding(Gas)氮氮化化(气气体体)Ferritic-Nitrocarburizing(Gas orSalt)铁铁酸酸盐盐-氮氮碳碳共共渗渗(气气体体或或盐盐)Process Table C-Aluminum工工艺艺表表C铝铝合合金金Aluminum Heat Treatment铝铝合合金金热热处处理理Process Table D-Ferrous工工艺艺表表D铁铁基基金金属属Induction Heat Treating感感应应热热处处理理Process Table E工工艺艺表表EAnnealing退退火火Norma
5、lizing正正火火Stress-Relieving去去应应力力退退火火Current Quality Certification(s):目目前前的的质质量量认认证证水水平平Date of Re-assessment(if necessary):重重新新评评估估日日期期(如如有有需需要要)Personnel Contacted:联联系系人人Name:姓姓名名Title:职职位位Phone:电电话话Email:邮邮件件Auditors/Assessors:审审核核人人Name:姓姓名名Company:公公司司Phone:电电话话Email:邮邮件件Number of Not Satisfacto
6、ry Findings:不不满满意意项项目目数数Number of Needs Immediate Action Findings:需需要要马马上上改改进进的的项项目目数数Number of Fail Findings in the Job Audit(s):作作业业审审核核中中不不合合格格品品数数CQI-9Special Process:Heat Treat System AssessmentVersion 2,Issue 8/07Special Process:Heat Treat System Assessment 特特殊殊过过程程：热热处处理理过过程程评评估估Assessment 评评
7、估估QuestionNumber 问问题题序序号号Question 问问题题Requirements and Guidance 要要求求/指指导导Objective Evidence客客观观证证据据N/A不不适适合合Satisfactory 满满意意Not Satisfactory不不满满意意Needs ImmediateAction 需需要要及及时时采采取取的的措措施施Section 1-Management Responsibility&Quality Planning 管管理理职职责责和和质质量量策策划划1.1Is there a dedicated andqualified heat
8、treat person on-site?To ensure readily available expertise,there shall be adedicated and qualified heat treat person on site.Thisindividual shall be a full-time employee and the position shallbe reflected in the organization chart.A job description shallexist identifying the qualifications for the p
9、osition includingmetallurgical and heat treat knowledge.The qualifications shallinclude a minimum of 5 years experience in heat treatoperations or a combination of a minimum of 5 years of formalmetallurgical education and heat treat experience.1.1现现场场是是否否配配备备有有资资力力的的热热处处理理专专业业人人员员?确确保保现现场场有有一一位位专专业业
10、的的热热处处理理人人员员，这这人人必必须须是是全全职职员员工工，同同时时他他的的职职位位应应在在组组织织结结构构图图中中体体现现出出来来，应应该该存存在在工工作作职职位位说说明明，其其中中须须对对这这个个人人的的能能力力（包包括括金金相相和和热热处处理理知知识识）进进行行鉴鉴别别，需需有有五五年年以以上上的的热热处处理理操操作作经经验验（至至少少五五年年），或或者者是是经经过过正正规规的的金金属属学学教教育育和和热热处处理理经经验验加加起起来来有有五五年年也也行行。1.2Does the heat treater performadvanced quality planning?The org
11、anization shall incorporate a documented advancequality planning procedure.A feasibility study shall beperformed and internally approved for each part.Similar partscan be grouped into part families for this effort as defined bythe organization.After the part approval process is approvedby the custom
12、er,no process changes are allowed unlessapproved by the customer.The heat treater shall contact thecustomer when clarification of process changes is required.This clarification of process changes shall be documented.1.2是是否否进进行行热热处处理理的的先先期期产产品品质质量量策策划划？（APQP）公公司司应应该该根根据据文文件件化化的的APQP 程程序序运运行行，每每个个零零件件
13、都都应应该该执执行行可可行行性性研研究究并并获获得得内内部部批批准准。相相似似产产品品可可以以归归为为一一类类，这这由由公公司司自自己己定定义义。一一旦旦 APQP 经经过过客客户户的的批批准准，就就不不得得有有任任何何的的更更改改，除除非非得得到到客客户户再再次次批批准准。当当有有些些工工艺艺过过程程确确实实需需要要更更改改时时，热热处处理理人人员员需需与与客客户户联联系系，并并要要做做出出相相应应的的数数据据记记录录。CQI-9Special Process:Heat Treat System AssessmentVersion 2,Issue 8/071.3Are heat treat
14、FMEAs up todate and reflecting currentprocessing?The organization shall incorporate the use of a documentedFailure Mode and Effects Analysis(FMEA)procedure andensure the FMEAs are updated to reflect current part qualitystatus.The FMEA shall be written for each part or part family or theymay be proce
15、ss-specific and written for each process.In anycase,they shall address all process steps from part receipt topart shipment and all key heat treat process parameters asdefined by the organization.A cross-functional team shall beused in the development of the FMEA.All specialcharacteristics,as defined
16、 by the organization and itscustomers,shall be identified,defined,and addressed in theFMEA.1.3热热处处理理的的故故障障失失效效模模式式和和影影响响分分析析(FMEA)是是否否是是最最新新的的，并并且且是是否否与与当当前前过过程程相相一一致致公公司司该该具具有有文文件件化化的的FMEA管管理理程程序序，并并确确保保FMEA得得到到更更新新以以反反映映当当前前零零件件的的质质量量状状态态。每每个个零零件件或或每每个个零零件件族族都都应应该该建建立立FMEA，或或者者FMEA也也可可以以按按过过程程来来编编
17、写写，要要覆覆盖盖每每个个过过程程，要要体体现现从从收收到到零零件件到到发发出出零零件件的的所所有有过过程程步步骤骤和和所所有有关关键键的的过过程程参参数数。应应由由跨跨职职能能的的小小组组来来发发展展完完善善FMEA，公公司司或或客客户户指指出出的的重重要要或或关关键键特特性性应应得得到到识识别别、定定义义并并标标在在FMEA中中。Special Process:Heat Treat System Assessment 特特殊殊过过程程：热热处处理理过过程程评评估估Assessment 评评估估QuestionNumber 问问题题序序号号Question 问问题题Requirements
18、and Guidance 要要求求/指指导导Objective Evidence客客观观证证据据N/A不不适适合合Satisfactory 满满意意Not Satisfactory不不满满意意Needs ImmediateAction 需需要要及及时时采采取取的的措措施施CQI-9Special Process:Heat Treat System AssessmentVersion 2,Issue 8/071.4Are heat treat process controlplans up to date and reflectingcurrent processing?The organiza
19、tion shall incorporate the use of a documentedControl Plan procedure and ensure the Control Plans areupdated to reflect current controls.The Control Plans shall be written for each part or part familyor they may be process-specific and written for each process.In any case,they shall address all proc
20、ess steps from partreceipt to part shipment and identify all equipment used and allkey heat treat process parameters as defined by theorganization.A cross-functional team,including a production operator,shallbe used in the development of Control Plans,which shall beconsistent with all associated doc
21、umentation such as workinstructions,shop travelers,and FMEAs.All specialcharacteristics,as defined by the organization and itscustomers,shall be identified,defined,and addressed in theControl Plans.Sample sizes and frequencies for evaluation ofprocess and product characteristics shall also be addres
22、sedconsistent with the minimum requirements listed in theProcess Tables,Sections 3.0 and 4.0.1.4热热处处理理控控制制计计划划是是否否是是最最新新的的，是是否否能能反反映映目目前前的的过过程程公公司司应应该该有有文文件件化化的的控控制制计计划划管管理理程程序序，并并确确保保控控制制计计划划得得到到更更新新，以以反反映映当当前前的的控控制制过过程程。控控制制计计划划适适用用于于每每个个零零件件或或零零件件族族，也也可可以以按按照照特特定定的的过过程程来来编编写写，要要体体现现从从来来料料接接收收到到零零
23、件件发发运运的的所所有有过过程程步步骤骤、关关键键的的过过程程参参数数和和所所使使用用的的设设备备。包包括括生生产产操操作作工工在在内内的的跨跨职职能能小小组组应应该该起起到到发发展展完完善善控控制制计计划划的的作作用用，控控制制计计划划应应该该与与作作业业指指导导书书（Work Instructions)、工工艺艺流流程程卡卡（Shop travelers）、FMEA等等保保持持一一致致性性。所所有有经经公公司司和和客客户户指指定定的的重重要要或或关关键键特特性性应应得得到到识识别别、定定义义和和体体现现。针针对对过过程程和和产产品品特特性性评评估估的的样样本本大大小小和和抽抽样样频频率率应
24、应该该与与该该过过程程表表中中的的3.0和和4.0节节中中的的最最低低要要求求保保持持一一致致。Special Process:Heat Treat System Assessment 特特殊殊过过程程：热热处处理理过过程程评评估估Assessment 评评估估QuestionNumber 问问题题序序号号Question 问问题题Requirements and Guidance 要要求求/指指导导Objective Evidence客客观观证证据据N/A不不适适合合Satisfactory 满满意意Not Satisfactory不不满满意意Needs ImmediateAction 需需
25、要要及及时时采采取取的的措措施施CQI-9Special Process:Heat Treat System AssessmentVersion 2,Issue 8/071.5Are all heat treat related andreferenced specificationscurrent and available?Forexample:SAE,AIAG,ASTM,General Motors,Ford,andDaimlerChrysler.To ensure all customer requirements are both understood andsatisfied,th
26、e organization shall have all related heat treat andcustomer referenced standards and specifications available foruse and a method to ensure that they are current.Suchstandards and specifications include,but are not limited to,those relevant documents published by SAE,AIAG,ASTM,General Motors,Ford,a
27、nd DaimlerChrysler.The organizationshall have a process to ensure the timely review,distribution,and implementation of all customer and industry engineeringstandards/specifications and changes based on customer-required schedule.Timely review should be as soon aspossible and shall not exceed two wor
28、king weeks.Theorganization shall document this process of review andimplementation,and it shall address how customer andindustry documents are obtained,how they are maintainedwithin the organization,how the current status is established,and how the relevant information is cascaded to the shop floorw
29、ithin the two-week period.The organization shall identify whois responsible for performing these tasks.1.5所所有有相相关关的的或或引引用用的的热热处处理理规规范范是是否否是是最最新新的的、可可用用的的？比比如如：SAE，AIAG（汽汽车车工工业业执执行行小小组组），ASTM（美美国国材材料料测测试试协协会会），通通用用，福福特特和和克克莱莱斯斯勒勒等等用用的的规规范范。为为了了确确保保所所有有客客户户的的要要求求都都能能被被理理解解，公公司司应应该该有有相相关关的的热热处处理理和和客客户户
30、参参考考标标准准，并并且且在在使使用用时时要要确确保保是是最最新新的的版版本本。这这些些标标准准和和规规范范包包括括但但不不限限于于SAE，AIAG，ASTM，通通用用，福福特特，克克莱莱斯斯勒勒等等发发布布的的相相关关文文件件。公公司司应应该该有有一一个个形形成成文文件件的的过过程程，适适时时评评审审、分分发发和和执执行行顾顾客客的的工工程程标标准准和和规规范范（Customerrequirments），该该过过程程一一般般不不超超过过两两周周。公公司司应应该该对对该该过过程程的的评评审审和和执执行行情情况况文文件件化化，以以文文件件规规定定由由谁谁执执行行、如如何何得得到到、如如何何维维护
31、护、如如何何建建立立最最新新状状态态跟跟踪踪和和如如果果传传递递到到生生产产现现场场？Special Process:Heat Treat System Assessment 特特殊殊过过程程：热热处处理理过过程程评评估估Assessment 评评估估QuestionNumber 问问题题序序号号Question 问问题题Requirements and Guidance 要要求求/指指导导Objective Evidence客客观观证证据据N/A不不适适合合Satisfactory 满满意意Not Satisfactory不不满满意意Needs ImmediateAction 需需要要及及时
32、时采采取取的的措措施施CQI-9Special Process:Heat Treat System AssessmentVersion 2,Issue 8/071.6Is there a written processspecification for all activeprocesses?The heat treater shall have written process specifications forall active processes and identify all steps of the processincluding relevant operating para
33、meters.Examples ofoperating parameters include process temperatures,cycletimes,load rates,atmosphere or gas flow settings,beltspeeds,quench agitation speeds,etc.Such parameters shallnot only be defined,they shall have operating tolerances asdefined by the organization in order to maintain processcon
34、trol.All active processes should have a written processspecification.These process specifications may take the form of workinstructions,job card,computer-based recipes,or other similardocuments.1.6对对所所有有的的操操作作过过程程是是否否有有书书面面的的过过程程规规范范？对对所所有有的的操操作作过过程程都都应应有有书书面面的的过过程程规规范范，并并包包含含所所有有过过程程的的步步骤骤和和相相关关操操作
35、作参参数数，这这些些相相关关操操作作参参数数包包括括过过程程温温度度、时时间间周周期期、装装载载率率、气气氛氛或或流流量量设设置置、传传送送速速度度、淬淬火火搅搅动动速速度度等等，并并应应确确定定其其公公差差范范围围以以便便于于进进行行控控制制。这这些些过过程程规规范范可可以以采采用用工工作作指指导导书书、作作业业卡卡、计计算算机机系系统统的的参参数数设设定定表表单单（Computer-basedComputer-based recipesrecipes）或或其其它它类类似似的的文文件件形形式式。Special Process:Heat Treat System Assessment 特特殊殊
36、过过程程：热热处处理理过过程程评评估估Assessment 评评估估QuestionNumber 问问题题序序号号Question 问问题题Requirements and Guidance 要要求求/指指导导Objective Evidence客客观观证证据据N/A不不适适合合Satisfactory 满满意意Not Satisfactory不不满满意意Needs ImmediateAction 需需要要及及时时采采取取的的措措施施CQI-9Special Process:Heat Treat System AssessmentVersion 2,Issue 8/071.7Has a val
37、id product capabilitystudy been performed initiallyand after process equipmenthas been relocated,or had amajor rebuild?To demonstrate each process is capable of yieldingacceptable product the organization shall perform productcapability studies for the initial validation of each process,afterrelocat
38、ion of any process equipment,&after a major rebuild ofany equipment.The organization shall define what constitutesa major rebuild.Initial product capability studies shall beconducted for all heat treat processes per furnace line definedin scope of work&in accordance with customer requirements.A furn
39、ace line may include a combination of equipment that isintegrated in the performance of a heat treatment process,e.g.,hardening,quenching,and tempering.Capability studytechniques shall be appropriate for the heat treat productcharacteristics,e.g.,tensile strength,case depth,hardness.Any specific cus
40、tomer requirements shall be met,in theabsence of customer requirements,the organization shallestablish acceptable ranges for measures of capability.Anaction plan shall exist to address the steps to followed in casecapability indices fall outside customer requirements orestablished ranges.Larry:与机加工过
41、程不同，适用于连续性数据的 Xbar-R 控制图不适合于热处理的产品特性。企业应遵守顾客指定的能力研究规范，如果没有顾客规范，企业应自己制定。推荐采用“装炉路线图法”，亦 loadmapping.1.7生生产产初初始始阶阶段段、过过程程设设备备重重新新布布置置或或重重组组重重修修之之后后是是否否进进行行了了有有效效的的能能力力验验证证？为为了了却却确确保保每每个个过过程程能能够够生生产产出出可可接接受受的的产产品品，供供应应商商应应对对每每一一个个过过程程进进行行生生产产能能力力研研究究，包包括括在在初初始始验验证证、任任何何过过程程设设备备重重新新布布置置或或重重组组重重修修（应应定定义义哪
42、哪些些地地方方要要重重组组重重修修）之之后后。初初始始能能力力研研究究应应包包括括指指定定了了年年度度工工作作范范围围的的每每一一条条热热处处理理炉炉生生产产线线的的每每台台炉炉子子。一一条条热热处处理理炉炉生生产产线线可可能能包包括括了了不不同同热热处处理理工工艺艺的的设设备备，如如：渗渗碳碳炉炉、淬淬火火炉炉、回回火火炉炉。能能力力研研究究技技术术应应针针对对热热处处理理产产品品特特性性，这这些些特特性性包包括括抗抗拉拉强强度度、硬硬化化层层深深度度、硬硬度度等等。任任何何顾顾客客的的特特殊殊要要求求均均应应满满足足，当当没没有有顾顾客客特特殊殊要要求求时时，公公司司应应建建立立一一个个可
43、可接接受受的的范范围围（AcceptableAcceptable rangesranges）以以测测量量过过程程能能力力，一一旦旦超超过过顾顾客客的的特特殊殊要要求求和和内内部部规规定定的的接接受受准准则则时时，应应采采取取行行动动计计划划对对那那一一步步骤骤进进行行跟跟踪踪。Special Process:Heat Treat System Assessment 特特殊殊过过程程：热热处处理理过过程程评评估估Assessment 评评估估QuestionNumber 问问题题序序号号Question 问问题题Requirements and Guidance 要要求求/指指导导Objecti
44、ve Evidence客客观观证证据据N/A不不适适合合Satisfactory 满满意意Not Satisfactory不不满满意意Needs ImmediateAction 需需要要及及时时采采取取的的措措施施CQI-9Special Process:Heat Treat System AssessmentVersion 2,Issue 8/071.8Does the heat treater collectand analyze data over time,and react to this data?The analysis of products and processes ove
45、r time can yieldvital information for defect prevention efforts.The organizationshall have a system to collect,analyze,and react to product orprocess data over time.Methods of analysis shall include ongoing trend or historicaldata analysis of product or process parameters.Theorganization shall deter
46、mine which parameters to include insuch analysis.1.8热热处处理理者者是是否否一一直直收收集集并并分分析析数数据据并并针针对对数数据据作作出出适适当当的的反反应应？定定期期分分析析热热处处理理产产品品和和过过程程可可以以获获得得非非常常重重要要的的防防错错信信息息。热热处处理理设设备备应应有有一一个个全全过过程程收收集集、分分析析、和和反反映映产产品品和和过过程程数数据据的的系系统统。这这些些分分析析方方法法包包括括对对重重要要产产品品或或过过程程参参数数的的历历史史数数据据分分析析或或目目前前的的走走势势分分析析。公公司司可可以以自自己己决决
47、定定哪哪些些数数据据应应纳纳入入分分析析范范围围。1.9Is management reviewing theheat treat monitoring systemevery 24 hours?Management shall review the furnace monitoring systems atintervals not to exceed 24 hours.The heat treat monitoringsystem includes but is not limited to temperature strip charts,atmosphere strip charts,
48、computer data logs,furnace andoperator logs,etc.The management review shall include efforts to detect out-of-control conditions or alarm conditions.The process ofreviewing the furnace data shall be documented and thisrequirement also applies to computerized data.1.9热热处处理理管管理理人人员员是是否否每每24小小时时审审查查一一次次
49、热热处处理理炉炉监监控控系系统统（Furnace MonitoringSystems）？热热处处理理管管理理者者应应每每24小小时时审审查查一一次次热热处处理理监监控控系系统统，热热处处理理监监控控系系统统包包括括温温度度走走势势表表、气气氛氛走走势势表表、电电脑脑数数据据标标识识，炉炉子子和和操操作作员员记记录录等等。管管理理审审核核包包括括对对失失控控状状态态或或报报警警状状态态的的探探测测，对对炉炉子子数数据据审审查查的的过过程程和和电电脑脑数数据据都都应应该该以以文文件件形形式式记记录录下下来来。1.10Are internal assessmentsbeing completed o
50、n an annualbasis,at a minimum,usingAIAG HTSA?The organization shall conduct internal assessments on anannual basis,at a minimum,using the AIAG HTSA.Special Process:Heat Treat System Assessment 特特殊殊过过程程：热热处处理理过过程程评评估估Assessment 评评估估QuestionNumber 问问题题序序号号Question 问问题题Requirements and Guidance 要要求求/指指