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Aiag Cqi-9 Special Processes

Assessment of Heat Treatment Process

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June 2018
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Heat Treating Industries Production And Manufacturing Business Manufacturing And Engineering

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CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 2 1 nd Edition CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group ABOUT AIAG Purpose Statement Statement Founde Founded d in 1982, 1982, AIAG AIAG is a global globally ly recogn recognize ized d organi organiza zatio tion n where where OEMs and and suppli suppliers ers unite unite to addres address s and resolv resolve e issue issues s affect affecting ing the worldw worldwide ide automo automotiv tive e supply supply chain. chain. AIAG's AIAG's goals goals are to reduce reduce cost cost and complex complexity ity throug through h collab collabora oration tion;; improve improve produc productt quality quality,, health, health, safety safety and the enviro environme nment; nt; and optimize speed to market throughout the supply chain. AIAG Organization Organization IAG IAG is made made up of a board board of dire directo ctors, rs, an execu executiv tive e direc directo tor, r, execu executiv tives es on loan loan from from memb member er compani companies, es, associ associate ate directo directors, rs, a full-time full-time staff, staff, and volunt volunteer eers s servin serving g on project project teams. teams. Direct Directors ors,, departme department nt manage managers, rs, and program program manage managers rs plan, plan, direct direct and coordi coordinate nate the associ associati ation’ on’s s activi activitie ties s under the direction of the executive executive & director. director. AIAG Projects Volunteer committees focus on business processes or supporting technologies and methodologies. They cond conduc uctt rese resear arch ch and and deve develo lop, p, publ publis ish, h, and and prov provid ide e trai traini ning ng on stan standa dard rds, s, conv conven enti tion ons, s, stan standa dard rd busine business ss practi practices ces,, white white papers papers,, and guidel guideline ines s in the areas areas of automa automatic tic identifi identificati cation on,, CAD/CA CAD/CAM, M, EDI/e EDI/ele lect ctron ronic ic comme commerc rce, e, conti continu nuou ous s quali quality ty impro improve vemen ment, t, heal health th focus focus,, mater materia ials ls and and proje project ct mana manage geme ment nt,, occu occupa pati tion onal al heal health th & safe safety ty,, retu return rnab able le cont contai aine ners rs and and pack packag agin ing g syst system ems, s, transportation/customs and truck & heavy equipment. AIAG PUBLICATIONS An AIAG publication publication reflect reflect a consensus consensus of those substantially substantially concerned with its cope and provisions. provisions. An AIAG publication publication is intended intended as a guide to aid aid the manufacturer, the consumer consumer and the general public. The existence of an AIAG publication does not in any respect preclude anyone from manufacturing, marketing purchasing or us ing products, processes, or procedures not conforming to the publication. CAUTIONA CAUTIONARY RY NOTICE AIAG publications a re subject to periodic review and users are cautioned to obtain the latest editions. MAINTENANCE ROCEDURE Recogn Recognizi izing ng that this this AIAG AIAG public publicati ation on may not cover cover all circums circumstanc tances es,, AIAG AIAG has establ establish ished ed a mainte maintenan nance ce procedure. procedure. Please Please refer to the Maintenance Maintenance Request Request Form at the back of this document to submit a request. Published by: Au to mo ti ve In d us tr y Ac ti on Gr ou p 26200 Lahser Road, Suite 200 Southfield, Michigan 48033 Phone: (248) 358-3570 • Fax: (248) 358-3253 APPROVAL APPROVAL STATUS The AIAG Quality Quality Steering Steering Committee Committee and designated designated stakeholders stakeholders approved this document document for publicati publication on on August 1, 2007. AIAG COPYRIGHT AND TRADEMARK NOTICE: The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. Copy Copyri righ ghtt is not not clai claime med d as to any any part part of an orig origin inal al work work prep prepar ared ed by a U.S. U.S. or stat state e gove govern rnme ment nt offic officer er or empl employ oyee ee as part part of the the person's official duties. Al rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part part of such such cont conten ent. t. The The infor informa mati tion on is not not to be sold sold in part part or whol whole e to anyo anyone ne with within in your your orga organi niza zati tion on or to anot anothe herr comp compan any. y. Copy Copyri righ ghtt infr infrin inge geme ment nt is a viol violati ation on of fede federa rall law law subj subjec ectt to crimi crimina nall and and civi civill pena penalt ltie ies. s. AIAG AIAG and and the the Autom Automot otiv ive e Indu Industr stry y Acti Action on Group are registered service marks of the Automotive Industry Action Group. © 2007 Automotive Industry Action Group 2 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 FOREWORD Auto Automo moti tive ve Indu Indust stry ry Acti Action on Grou Group p (AIA (AIAG) G) com committ mittee eess are are made ade up of volu volunt ntee eers rs from from memb member er compan companies ies in the autom automoti otive ve indus industry try.. The work work of prepa preparin ring g proces processs audit auditss is done done by AIAG AIAG techni technical cal committees. The The main main task task of tech techni nica call comm committ ittee eess is to prepa prepare re Autom Automot otive ive Stan Standa dards rds and and Syst System em Requ Require ireme ment nts. s. Draft Draft docume documents nts adopte adopted d by the techni technical cal commit committee teess are circula circulated ted to the Steeri Steering ng Commit Committee tee for review review and and cons consen ensu suss appr approv oval al.. Publ Public icat atio ion n of the the docu docume ment ntss requ requir ires es appr approv oval al by the the Qual Qualit ity y Stee Steeri ring ng Committee. The Quality Quality Steerin Steering g Commit Committee tee would would like like to acknow acknowledg ledgee and thank thank the follow following ing indivi individua duals ls and their companies who have contributed time and effort to the development of this document. 3 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group ACKNOWLEDGEMENTS Core Members: Pete Batche — Robert Bosch LLC Mel Dilley — DaimlerChrysler DaimlerChrysler Corp. Corp. Curt Holmes — Commercial Commercial Steel Treating Treating Corp. Ed Jamieson — Bodycote Bodycote Thermal Processing Processing Young Kim — Ford Motor Company Brett Lenhausen — General Motors Corporation Philip Mikula — TRW Automotive, Inc. Murli Prasad — General Motors Motors Corporation Supporting Members: Todd Bensinger — DaimlerChrysler DaimlerChrysler Corp. Scott Brodersen Brodersen — DaimlerChrysle DaimlerChryslerr Corp Dave Calkins — DaimlerChrysler Corp Leonard Leonard Gadzinski — Acument Global Technologies Technologies North America Tim Green — BSI Americas, Inc. Dave Hernacki Hernacki — Commercial Commercial Steel Treating, Treating, Corp. Dean Higdon — Acument Acument Global Technologies Technologies North America Jeff Martin — ZF Friedrichshafen, AG M i k e O b e r g — I n d u c t i on on S e r v i c e s , I n c . Mike Wiezbowski Wiezbowski — DaimlerChrysler DaimlerChrysler Corp. Corp. 4 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 TABLE OF CONTENTS ABOUT AIAG ...................................................................................................................................................................................................... 1 FORWORD ............................ ................................................ .................................. ................. ................. ............................ .................................. .................................. ................. ................. ............................ .............................. ................ 3 ACKNOWLWDGEMENT ACKNOWLWDGEMENTS........ S...................... .................................. .................................. .................................. .................................. .................... ................... ........................... .................................. ........................... ....... 4 INTRODUCTION............... INTRODUCTION............................. ................. ................. ............................ .................................. .................................. ................. ................. ............................ .................................. .................................. .................... ...... 6 1 SCOPE............................... SCOPE................................................... ........................................ .................................. ......................... ........................ ........................... .................................. .................................. ................. ................. ................... ..... 8 1.1 GENERAL.............................................................................................................................................................................................. 8 1.2 APPLICATION APPLICATION............. ........................... .................................. .................................. ................................... ................................... ............................ ............................ .................................. ................................ ............ 8 1.3 REFERENCE......................................................................................................................................................................................... 9 2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE ........................... ................................ ................... ............................ .................................. .............................. .......... 10 3 SP ECIAL PRO CESS: HEAT TREAT SYSTEM ASSES SMENT PR OCEDU RE ........... ................ ........... ........... .......... ........... ........... ........... ........... ........... ........... ........... ......... ... 11 INSTRUCTIONS INSTRUCTIONS FOR COMPLETING COMPLETING THE COVER SHEET............................. SHEET................................ ................. ............................ .................................. .............................. .......... 12 SPECIAL PROCESS: HEAT TREAT ASSESSMENT ASSESSMENT FORMS............ FORMS.......................... .................................. .................................. .................. ................. ......................... ............ 18 INSTRUCTIONS INSTRUCTIONS FOR COMPLETING COMPLETING THE JOB AUDIT................................ AUDIT............................................. ........................... .................................. .................................. .................... ...... 37 JOB AUDIT FORM................................ FORM............................................ .......................... ................................... ................................... .................................. .................................. ................. ................. ....................... ......... 38 APPENDIX A — PROCESS TABLES.........................................................................................................................................................42 APP END IX B — GLO SSA RY .................................................... ....................................................................................................... ............................................................................................................ ................................................................. ........ 66 MAINTENANCE REQUEST................................................................................................................................................... 69 5 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group INTRODUCTION General The work of prepar preparing ing CQI 9: Special Special Process: Process: Heat Heat Treat Treat System System Assess Assessment ment (HTSA), Second Second Edition Edition,, was was carr carrie ied d out out thro throug ugh h the the AIAG AIAG Heat Heat Trea Treatt Work Work Grou Group. p. Thes These e hea heat tre treat requ requir irem emen ents ts are complementary to customer and product standards. The HTSA can be used used to assess assess an organi organiza zatio tion's n's ability ability to meet the requi requireme rements nts in this this asses assessme sment, nt, as well well as cust custome omer, r, regu regula lato tory ry,, and and the orga organiz nizati ation on's 's own own requir requireme ement nts. s. The The HTSA HTSA can can also also be used used between between an organization and its suppliers. suppliers. In the the HTSA, HTSA, the the word word "shal "shall" l" indic indicate ates s a requi requireme rement nt for purp purpos oses es of the the self self asse assess ssmen ment. t. Fail Failure ure to meet meet the the requ require iremen ments ts resu results lts in an asse assess ssmen mentt that that is eithe eitherr “Not “Not Satis Satisfac facto tory ry”” or “Need “Needs s Immed Immedia iate te Action”. The word “should” indicates a recommendation. Where the term "such as" is used, any suggestions suggestions given are for guidance only. Process Approach The HTSA supports supports the automotive process approach as described described in ISO/TS16949:20 ISO/TS16949:2002. 02. Heat Treat System Assessment Goals The goal of the HTSA HTSA is the develo developme pment nt of a heat heat treat treat manage management ment system system that that provid provides es for contin continual ual improvement, improvement, emphasizing emphasizing defect prevention prevention and the reduction of variation variation and waste in the supply chain. The The HTSA HTSA,, coup couple led d with with an inte intern rnat atio iona nally lly reco recogn gniz ized ed qual quality ity manag manageme ement nt syste system m and and appl applic icab able le customer-specific requirements, defines the fundamental requirements for heat treat management systems. The HTSA HTSA is intend intended ed to provid provide e a common common approach approach to a heat heat treat treat manag manageme ement nt syste system m for automo automotiv tive e production and service part organizations. Assessment Process Ongo Ongoin ing g asse assess ssmen ments ts shal shalll be condu conducte cted d annu annuall ally, y, unles unless s othe otherwi rwise se speci specifie fied d exam examin ine e the the cont contin inui uing ng comp compli lian ance ce with with the the HTSA HTSA.. Each Each asse assess ssme ment nt shal shalll organ organiza izatio tion' n's s syste systems ms usin using g the HTSA. HTSA. Succ Succes essi sive ve Job Job Audit Audits s (Secti (Section on 4.0 4.0 sample sample parts parts from from differe different nt automo automotiv tive e compon component ent manufact manufacture urers rs that that requi require re document. by the custo customer mer,, to reincl includ ude e a revi review ew of the the of this this docu documen ment) t) shal shalll compli complian ance ce to the HTSA HTSA The assess assessmen mentt shall shall use the proces process s approa approach ch to auditi auditing ng as identi identified fied by the requir requireme ements nts of ISO/TS ISO/TS 16949:2002. 6 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 Assessor Assessor Qualifications Qualifications Assessors(s) shall have the following specific experience to conduct the HEAT TREAT SYSTEM ASSESSMENT : 1. Be an expe experi rien ence ced d qual qualit ity y mana manage geme ment nt syst system em (QMS (QMS)) inte intern rnal al audi audito torr (for (for exam exampl ple, e, ISO/TS 16949:2002, ISO 9001:2000) 2. Asse Assess ssor or shal shalll posse possess ss heat heat treati treating ng knowl knowled edge ge.. Evide Evidenc nce e shal shalll inclu include de a minimu minimum m of 5 years years expe experie rienc nce e in heat heat treat treatin ing g or a combi combina natio tion n of forma formall metal metallu lurgi rgical cal educ educati ation on and and heat treating experience experience totalling totalling m inimum of 5 years. years. 3. Asse Assess ssor or shal shalll poss posses ess s know knowle ledg dge e of and and be famil familia iarr with with the appli applica catio tion n of auto automot motiv ive e qual quality ity core core tools tools inclu includin ding g statis statistic tical al proc proces ess s contro control, l, measu measurem remen ents ts syste system m analy analysis sis,, part approval, failure mode and effects analysis, and advanced quality planning. Note Note:: If more more than than one one asse assess ssor or is requ requir ired ed to meet meet the the abov above e qual qualif ific icat atio ions ns,, the the lead lead assessor shall be the person meeting the requirements in item #1. Other Requirements Requirements The orga organiz nizat atio ion n shall shall keep keep reco records rds as evide evidenc nce e of compl complian iance ce to the the requir requireme ements nts ident identifi ified ed in the the HTSA, HTSA, as well well as appr appropr opria iate te acti action on plans plans to addr addres ess s any unsati unsatisfa sfacto ctory ry ratin ratings gs.. Thes These e reco record rds s shal shalll be read readily ily availa available ble for for review review by any custo customer mer requ requiri iring ng compl complian iance ce to the the requ require iremen ments ts withi within n this this document. 7 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group 1 SCOPE 1.1 General This This docum documen entt specif specifies ies proces process s requir requireme ements nts for an organiz organizati ation on or its suppli suppliers ers perfor performin ming g appli applicab cable le heat treating, who need to   demonstr demonstrate ate abilit ability y to consiste consistentl ntly y provid provide e produc productt that that meets meets custom customer er and and applic applicabl able e regulatory requirements, and enhanc enhance e custom customer er satisf satisfact action ion throug through h the effect effective ive applic applicati ation on of the syste system, m, includ including ing processes for continual improvement of the system. The Heat Heat Treat Treat Syste System m Asses Assessmen smentt is applic applicabl able e to sites sites where where custom customer er-speci -specifie fied d parts parts for produ productio ction n and/or service are processed throughout throughout the a utomotive utomotive supply chain. 1.2 Application All requirements of the HTSA are generic and are intended to be applicable to all organizations performing the heat treat operations addressed in this document, regardless of type, size, and product. Note: Process Table E is only applicable to process affecting the final characteristics of the part. Five Five Proces Process s Tabl Tables es have have been been deve develo lope ped d and and the the appr approp opria riate te tabl table( e(s) s) is to be refe referen rence ced d durin during g the assessment. assessment. The Process Process Tables are specific to heat treat processes processes as noted below: Process Process Table A – Ferrous  Carburizing  Carbonitriding  Carbon Restoration or Correction  Neutral Hardening Hardening (Quench (Quench and Temper)  Austempering  Martempering  Tempering  Precipitation Precipitation Hardening Hardening – Aging Process Process Table B – Ferrous  Nitriding (Gas)  Ferritic Ferritic Nitrocarburizin Nitrocarburizing g (Gas or Salt) Process Table C – Aluminum Heat Treating Process Process Table D – Induction Heat Treating – Ferrous Ferrous Process Process Table E – Annealing, Annealing, Normalizing, Normalizing, and Stress Relieving  Conformance to CQI-9 is required for all organization that perform annealing, normalizing, or stress-relieving to achieve desired final characteristics of the part. 8 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 Note: Material producers of primary or raw materials, or any intermediate thermal treating process step(s) that do not affect the final characteristics characteristics of the part are exempt from conforming to the requirements in CQI-9. These Process Tables contain requirements for: 1. 2. 3. 4. 5. Process and Test Equipment Pyrometry Process Monitor Frequencies In-Process/Final Test Frequencies Quenchant Quenchant and Solution Solution Test Frequencies Frequencies The Process Tables specify the tolerances tolerances of process process parameters parameters and the frequencies frequencies for checking checking process process cont contro roll param paramet eters ers and and parts. parts. The Requ Require iremen ments/ ts/Gu Guide idelin lines es in the HTSA HTSA form form will will notif notify y the asse assess ssor or when to refer to the Process Tables. 1.3 Reference The followin following g standa standards rds are referen referenced ced in this document. document. The applic applicabil ability ity is limited limited to the subject subject matter referenced. Standard Number Title Standard’s Organization AMS 2750D Pyrometry SAE J415 Definition of the Heat Treating Terms Suface Hardness Testing With Files SAE Aerospace www.sae.org SAE International International www.sae.org SAE International International www.sae.org SAE J864 9 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group 2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE 1. Obtai btain n curre current nt copy copy of CQI-9 CQI-9 Spec Specia iall Proc Process ess:: Heat Heat Treat Treat Syste System m Asse Assess ssme ment nt,, 2nd 2nd edit editio ion n from AIAG. 2. Iden Identi tify fy all all heat heat trea treatt proce roces sses ses to which ich CQICQI-9 9 Speci pecia al Proce rocess ss:: Hea Heat Trea Treatt Syst Syste em Assessment 2nd edition applies (see CQI-9, CQI -9, 1 .2). Record these processes pr ocesses on the HTSA, Page 1. 3. Comp Comple lete te the the HTSA HTSA,, dete determ rmin inin ing g the the leve levell of comp compllianc iance e. A min minimum mum of one one job job audit udit (Section 4) shall be performed during each assessment. 4. Addr Addres ess s each each "Not Sati Satisf sfac acto tory ry"" item item and and dete determi rmine ne corre correcti ctive ve actio action, n, incl includ udin ing g root root caus cause e anal analy ysis sis and and impl implem emen enta tati tion on of the the corr corre espon spondi ding ng corr correc ecti tive ve acti action on(s (s). ). The The corr correc ecti tive ve acti action on(s (s), ), shal shalll be comp comple lete ted d with within in 90 days. ays. Reco Record rds s of the the corr correc ecti tive ve acti action on,, incl includ udin ing g verificatio verification, n, shall be be maintained. maintained. 5. “Need “Needs s Imme Immedi diat ate e Acti Action on”” requ requir ires es imme immedi diat ate e cont contai ainm nmen entt of susp suspe ect prod produc uct. t. Addr Addres ess s each each “Need “Needs s Immed Immedia iate te Acti Action on”” item item and and deter etermin mine e corr correc ectiv tive e acti action on(s (s), ), incl includ udin ing g root root caus cause e anal analy ysis sis and and impl implem emen enta tati tion on of the the corr corre espon spondi ding ng corr correc ecti tive ve acti action on(s (s). ). The The corr correc ecti tive ve acti action on(s (s)) shal shalll be comp comple lete ted d with within in 90 day days. Reco Record rds s of the the corr correc ecti tive ve acti action on,, incl includ udin ing g verification, shall be maintained. 6. Assessments shall be be conducted annually unless unless otherwise specified specified by the customer. customer. 10 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 3 SPECIAL SPECIAL PROCESS: PROCESS: HEAT TREAT ASSESSMENT INSTRUCTION FOR COMPLETING THE COVER SHEET.....................................................................12 COVER SHEET FORM..........................................................................................................................14 INSTRUCTIONS FOR COMPLETING SECTION 1-3 ................................................................................15 SECTION 1: MANAGEMENT MANAGEMENT R ESPONSIBILITY ESPONSIBILITY & QUALITY PLANNING ................. .......................... ............... .......18 .18 SECTION 2: FLOOR AND MATERIAL HANDLING RESPONSIBILITY......................... RESPONSIBILITY........................................25 ...............25 SECTION 3: EQUIPMENT .......................................... .................. ........................................... ........................................... ................................... ........... ....................31 .................. ..31 INSTRUCTIONS FOR COMPLETING THE JOB JOB AUDIT ........................................... ................... ........................ ..................... ................... ..........37 ........37 SECTION 4: JOB AUDIT.......................................................................................................................38 11 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group Instructions for completing the Cover Sheet 1. 2. 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 The stree streett addre address ss of the faci facilit lity y being being asses assessed sed;; P.O P.O Box numbers numbers may be given given as additi additiona onall information. 3. Phone Number: The phone number of the facility. If there there is no commo common n phone phone numbe numberr for the the facil facility ity,, the the phone phone number number of the the Opera Operatio tions ns Manager Manager or Qualit Quality y Manager shall be used. 4. Fax Number: The fax number of the facility. 5. Number of Heat Treat Employees Employees at this Facility: Facility: The The number of employees, salaried and hourly, associated with the heat treat operation at this facility. 6. Captive Captive Heat Treater (Y/N): (Y/N): Enter "Y" if this facility heat treats components for their own company. Enter "N" if the company does not heat treat any components for their own company. 7. Commercial Commercial Heat Treater (Y/N): Enter (Y/N): Enter "Y" if this facility heat treats components for companies other than their own company. Enter "N" if this facility does not heat treat any components for other companies. 8. Date of Assessment: Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be used to avoid confusion with different numeric formats. Example: May 3 – 4, 2006 9. Date of Previous Previous Assessment: Assessment: List List the date of the previous CQI-9 Special Process: Heat Treat System Assessment of this facility. 10. Type(s) of Thermal Thermal Processing Processing at this this Facility: Facility: Place a checkmark to designate all thermal process(es) performed at this facility. This information determines the appropriate Process Table that shall be used during the assessment. Processes not listed on the cover sheet are not part of the Heat Treat System Assessment. 11. Current Current Quality Quality Certificati Certification(s) on(s):: The The heat heat treate treaterr shall shall list list their their current current qualit quality y certif certific icati ations ons,, e.g., e.g., ISO/T ISO/TS S 16949:2002, 16949:2002, ISO 9000:2002. 9000:2002. Certificatio Certifications ns may be from 3rd party sources or customer customer quality certification certifications. s. If customer quality certification certification is given, then the year of the last assessment by the customer shall also be given. 12. Date of Re-assessment Re-assessment (if necessary): If necessary): If "Not Satisfactory" findings were observed from the original assessment, then then the heat heat treate treaterr shall shall addres address s each each item item and determ determine ine correc correctt action action,, includ including ing root cause cause analys analysis is and implementation of the corresponding corrective action(s). action(s). The date of the re-assessment shall be given here, and the appropriate Question(s) from Sections 1 – 4, in the original original assessme assessment, nt, shall be modified modified to reflect reflect that the evidence evidence,, relating relating to the implementati implementation on of the the correctiv corrective e action(s), has been observed. Also, the "Number of Not Satisfactory Findings" shall be modified as appropriate. 13. 13 . Personnel Contacted: L Contacted: L ist the name(s), title(s), phone number(s), and email addr addres ess( s(es es), ), ifif avai availa labl ble, e, of the principal participants from the heat treater's organization. 12 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 14. 14 . Auditors/Assessors: List Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), if available, of the auditor/assessor(s). 15. 15 . Number Number of "Not "Not Satisfa Satisfactor ctory" y" Findin Findings: gs: Enter Enter the number of "Not Satisfac Satisfactory tory"" findings findings observed during the assessment. 16. 16 . Number of “Needs “Needs Immediate Immediate Action” Action” Findings: Findings: Enter Enter the number of “Needs Immediate Action” finding observed during the assessment. assessment. 17. 17 . Number of “Fail” “Fail” Finding in the Job Audit Audit(s): (s): Enter the number of “Fail” findings observed from the job audit. 13 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group Special Process: Heat Treat Process Assessment Facility Name: ddress Phone Number ax Number umber of Heat Treat Em lo ees at this Facilit a tive Heat Treater Y/N Type(s) of Thermal Processing at this Facility: Process Process Table – Ferrous Ferrous Carburizin Carbonitridi idin Carbon Correction Neutral Hardenin uench uench & Tem Tem er Commercial Heat Treater (Y/N) Austempering / Martempering Date of Evaluation: Tem erin Precipitation Hardening /Aging ate of Previous Evaluation: Process Process Table Table B Ferrous Ferrous Nitriding (Gas) FerriticNitrocarburizing FerriticNitrocarburizing (Gas or Salt) Process Table C Aluminum luminum Heat Treatment Process Process Table Table D Fe rous rous Induction Heat Treatin Process T ble E nnealin Normalizing Stress-Rellevin Current Quality Certification(s) ate of Re- ssessment: if necessar necessar : ersonnel Contacted: ame: itle: uditors/Assesors: ame: Com an : umber umber of Not Not atisfa atisfact ctor or Findin Findin s: s: Phone: Email: Phone: Email: umber of Needs Immediate Action” Findin s: umber umber of Fall” Fall” Findin s in the the Job Job Audits: Audits: 14 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 Instructions for completing Sections 1 - 3 Sections Sections 1 - 3 contain questions and the requirements/guidanc requirements/guidance e for each question. The Sections are:  Section Section 1 – Management Management Respons Responsibility ibility & Quality Planning Planning  Section Section 2 – Floor Floor and Material Material Handling Handling Responsibility Responsibility  Section Section 3 – Equipment Equipment The asse assesso ssorr shal shalll asse assess ss the the heat heat treate treater's r's compl complian iance ce to Secti Section ons s 1 – 3 by compa compari ring ng the evid eviden ence ce presented presented by the heat treater to the requirements requirements listed in the "Requirements "Requirements and Guidance" Guidance" column. NOTE NOTE 1: In the the "Req "Requi uire reme ment nts s and and Guid Guidan ance ce"" col colum umn, n, the the word word "sh "shal all" l" ind indic icat ates es a requ requir irem emen entt and and the the term term "suc "such h as" as" indi indica cate tes s that that any any sugg sugges esti tion ons s given given are for guidance guidance only. NOTE NOTE 2: The The "Re "Requ quir irem emen ents ts and and Guid Guidan ance ce"" col colum umn n wil willl indi indica cate te to the the asse assess ssor or when when the the Proc Proces ess s Tabl Tables es are perti pertine nent nt to the Ques Questi tion ons. s. When When the the Process Tables are pertinent to the Question, the assessor shall assess the heat heat treater' treater's s complia compliance nce to the specifi specified ed section section(s) (s) in the Proce Process ss Tables. NOTE NOTE 3: If the the ques questi tion on is not not appli applicab cable le to the the heat heat treate treater, r, then then the the asse assess ssor or shall shall plac place e a checkm checkmar ark k in the the "N/A" "N/A" Asse Assess ssmen mentt colu column. mn. If the the obse observ rved ed eviden evidence ce is in complia compliance nce to the questio question, n, the assess assessor or shall shall note the evidence in the "Objective Evidence" column and place a check mark in the "Satisfac "Satisfactory tory"" column. column. If the observed observed eviden evidence ce is not in complia compliance nce to the questio question, n, then then the assess assessor or shall shall note the non-co non-compli mplianc ance e in the "Obj "Objec ecti tive ve Evid Eviden ence ce"" colu column mn and and plac place e a chec check k mark mark in the the "Not "Not Satisfactory" column. NOTE NOTE 4: Wher Where e non nonco conf nfor ormi ming ng prod produc uctt is is ide ident ntif ifie ied d in in the the ass asses essm smen entt of of a giv given en question the assessor shall place a check mark in the “Needs Immediate Action” (NIA) column. NIA requires immediate containment of suspect product. 15 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group General Notes for AMS 2750D AMS 2750D is refer enced in the Pyrometr y Section Secti on (Section (Sect ion 2.0) of the Process Proces s Tables . Organizati Organ izati ons and suppliers suppliers shall comply with the sections sections of AMS 2750D 2750D that reference reference thermoco thermocouple uples, s, the calibration of thermoco thermocoupl uples es and instrume instrumentatio ntation, n, and the procedu procedure re for conduc conducing ing furnace furnace temperatu temperature re unifor uniformity mity surveys surveys (TUS) see below. Exceptions Exceptions to this requirement requirement are listed below below in the respective sections. sections. Thermocouples and Instrumentation – Section Section 3.1 – Temperature Temperature Sensors (Thermocouples) (Thermocouples) – Secti Section on 3.2 3.2 –Instru –Instrumen menta tati tion on –Note: Note: Frequ Frequen ency cy reduc reductio tions ns per per AMS 2750 2750D D are not allowed by CQI-9 Exceptions Exceptions (Compliance (Compliance to the following sections sections are not required required b y CQI-9) Sectio Section n Number Number Expl Explan anati ation on 3. 2. 2.5.1 & 2 Temperature controlling instruments purchased prior 1 year after le release of AM S 2750D are exempt 3.2.5.1 and 3.2.5.2. 3.2.5.2. 3.2. 3.2.5. 5.3. 3.1 1 One One poin oint sen sensor sor inp input is acce accep ptabl table e. 3.2.5.5 Sensit nsitiv iviity chec hecks during ing calibrati ratio on are not required. to of System System Accuracy Accuracy Test (SAT) Procedure Procedure ( Section Section 3.4) – SAT shall be performed by by one of the two methods listed below. below. – CQI CQI-9 -9 requi require res s eith either er a (1) comp compara arati tive ve chec check k of the the cont contro roll tempe temperat ratur ure e sens sensor or (CTS) (CTS) to a calib calibrat rated ed test test tempe temperat rature ure sens sensor or (CTTS (CTTS)) or (2) resid residen entt thermoc thermocou ouple ple (R-T/C), (R-T/C), per AMS 2750D. (1) (1) The The CTS CTS shal shalll be +/+/- 5C (or (or 4:4:- 10F) 10F) of the the CTTS CTTS at a typi typica call oper operat atin ing g temp temper erat atur ure e rang range; e; this this chec check k shal shalll be perf perfor ormed med mont monthl hly. y. The The proc proced edur ure e shall follow AMS 2750D Section 3.4. (2) The relationship between the CTS and R-T/C at the operating temp temper erat atur ure e ran range shal shalll be with within in +/+/- 1C (or (or +/- 2F) 2F) of thei theirr rela relati tion onsh ship ip dete determi rmine ned d at the the time time of the the most most rece recent nt temp temper eratu ature re unifo uniformi rmity ty surv survey ey:: this this chec check k sha shall be perf perfor orme med d weekl eekly y. SAT SAT per per AMS 2750 2750D D Sect Sectio ion n 3.4 3.4 is not required with this method. – Any Any acti action ons s to corr correc ectt a fail failin ing g read readin ing g or vali valida date te a test test resu result lt shal shalll be documented – Type Type K and and N the thermoco rmocoup uple les s shal shalll be chec checke ked d month monthly ly for equi equipm pmen entt oper operat atin ing g at or above 760C (1400F) and changed annually at a minimum. – Type Type K and and N ther therm mocou ocoupl ples es shal shalll be chec checke ked d quart quarter erly ly for equi equipm pmen entt opera operatin ting g below 760C (1400F) and changed every two years at a minimum. – Type R and S thermocou thermocouple ples s shall shall be checked checked monthly monthly for equipme equipment nt operatin operating g at or above 7600 (1400F) and changed every two years at a minimum. Furnace Temperature Uniformity Survey (TUS) – Section Section 3.5.2 – Multiple Qualified Operating Temperatur Temperature e Ranges – Section Section 3.5.3 – furnace Modifications Section 3.5.4 – Furnace Repairs – Section 16 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 – Section Section 3.5.5 – Initial TUS   Mini Minimu mum m and and maxi maximu mum m temp temper eratu ature re rang ranges es shal shalll be test tested ed per per AMS 2750D. Exception: If the operating range of the Qualified Wor Work Zone is equal to or less than 85C (15 (153F) the then only one temp temper eratu ature re is requ requir ired ed to be test tested ed.. The The temp temper erat atu ure shal shalll be within the operating range of the Qualified Work Zone. Section Section 3.5.6 – Periodic Periodic TUS (For CQI-9. a m inimum of once per year periodic TUS is required) required) Mini Minimum mum and and maxim maximum um temp temper erat atur ure e rang ranges es shal shalll be test tested ed per per AMS 2750D. Exception: If the operating range of the Qualified Wor Work Zone is equal ual to or less that 35C 35C (15 (153F) 3F) then hen only one temp temper eratu ature re is requ requir ired ed to be test tested ed.. The The temp temper erat atu ure shal shalll be within the operating range of the Qualified Work Zone. Section Section 3.5.8 - Furnace Furnace Parameters During TUS Section Section 3.5.9 - Furnace Furnace Temperature at Insertion Insertion of TUS Sensors Sensors (Thermocouples) Section Section 3.5.10 3.5.10 - Load Load Condition Section Section 3.5.11 - Furnace Atmosphere Atmosphere During TUS TUS Sec Sectio tion n 3.5.1 3.5.13 3 - Batc Batch h Furna Furnace ces, s, Salt Salt Baths Baths.. Cont Control rolle led d Tempe Tempera ratu ture re Liqui Liquid d Baths, and Fluidized Bed Furnaces EXCEPT:              3.5. 3.5.13 13.3 .3.2 .2:: CQICQI-9 9 requ requir ires es that that data data from from the the TUS TUS sen sensors sors is automatically recorded. Section Section 3.5.14 - Cont inuous inuous and Semi-Continuous Semi-Continuous Furnaces Sec Secti tion on 3.5. 3.5.15 15 - Alte Altern rnat ativ ive e Testi Testing ng Meth Method ods s for for Cont Contin inuo uous us and and Semi Semi-Continuou Continuous s Furnaces or Furnaces Furnaces with Retorts or Muffles Section Section 3.5.16 - Temperature Uniformity Uniformity Survey Sensor Sensor Failures Secti Section on 3.5. 3.5.1 18- Relo Reloca catt tton on of Hot Hot or Cold Cold Reco Record rdin ing g Sens Sensors ors for for Clas Class s A or C Instrumentation Section Section 3.5.20 - Temperature Temperature Uniformity Survey instrumenta instrumentation tion Section Section 3.5.21 3.5.21 - Temperature Temperature Uniformity Survey Report 17 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i d d i o e e e t c D m A m I y r o t t o c a N f s i t a S t n e m s s e s s A r y o t c a f s i t a S t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R g n i n n a l P y t i l a u Q y t i l i b i s n o p s e R t n e m e g a n a M 1 n o i t c e S . . e l n e e c a o e t g l n h y s d 5 e i a a i s n o l o e f x o r r l m r s e e r p e n o r w o o m s f o p e e l i m l x t p a u h i f e n n o e t t e h s k m t o t , a e t h i i s o t s a e r n a r e e i m i n n p a i s t i r e m r t o h e t - d t i r e a r t t e t e a l t a p y t e p t u t i o p e f c r r a e t 5 a e x h o e d a f h e c e d a f l s f h l o d u s e e e e i e b r e d n d c t r l m n i b f o n n t u l l i l e b t a i a a a l a l a b o i u h l j a l l e m n a h i o a c a i i s l n t v q l f c h a A i i i n a a d a h t . l s i g a m c n r s e u y a u s r l u n i a u a d d c f n h q l i d o d n v i o c e t a t i e o l e a e i e t d t i a i h n a r s n t e i a c r n i o e o c c o i m f i e i g i i g p r s p t n g l d i a i x t a e a r u n e h e z y n u s i f i u i l h i d n d T q s b l t n a . d e a e a t u e r n l a m t g e e c h o e t n r d i n T e T b s a o i i y o c m s s t s e o e i n i t d d e a e h e h b n t e h e v i g h t T o s n n r y s a e w e p d b e h h . l e c c T d l m y p a a p e h u t o r r i u . c l r e i s i y o d r p s u o e e s m q i l r d b n l e m o e s a g f i c o t r s a n e e a e r o t s e v r s u a f t e b d o p s g c i r u A i n c n e . n s p t p a e e o s h a a n h e a r d a r c t u e o d n t t y h g c p e a s r r r , t n r o a e b h a c t f o o d r p d c s c r a f e m s e n e p i p m o v t c s e e t o a c l g r r s s r l i h t s o n f o l a h t u p n e r i a i c r t p p h n c e i s n m r a o c r o a p S r t l e h e s p o f s n p e f t e f o t i y t . A l l f o t n a o l b r a i y s . b u h . z a l a i e n i s n n d n u a p l i i e o d t e a q h h m t o o i t i n g e a d w t r c f a i c s a a e z e o r a v l o n l c f c m i i y e n o e f a d t a r a t i i r r e d v t r g p e a a a u c u r h r p r r e l l o o a T A S f p o a a t c c d e y e s e t h t b b c h t e f f d l f y o e a . E r n s e t n h i i l e f t s t u a t t l n e s A i e E a d s u r r r a e d a f n n q p w d s n , M o a e t m d a F o s r r d a i p s r P e o n l s t o a e s e d a r c l p t a e u d n t r e n e m h a t a f c h u v s , t t e f o t e o a n i p e e i s n m s d i h c s i t M r c y e a s t r h u n c e e e u a e m r r s c d o e i t p r r c h a a r e u t p p c h e e e s i r - t , h t s s u d c r s s o l A t c t e s s i e o s e p e l f s s . a i r r a c f e a t n r r e n i d o e F o n c a c i c r r o h d d o c a e r o t n p t o t y p r c n a i t i a d p n l s p r l z e a d s m i d a t l n e s a e ) e w b r o a n u i a a h c t n A f a e I e , s o E a b y . t c n d r g r d l a s s t r e e i o e n P M l p o p p s t o F u a m e e a b s a i i n t e l e h y c t z f a d ( P e h s h e s e l l i t z e r o i n d r s y y a A a , a A h n t t p s h e g d a n s E r h e k b s r s A g e i c l e . M o c o . o f i r s l d m E s y e A i o u y F a l r a l M t m E t u i n e i p e c a a e m r l d f a e n e h o n F t h a o l n e e M h d T d A P s T f f a a d T F t i n o i t s e u Q n o d n n o a s d r e e t p a c t a ? i d r e e e t t d t i s a a e e h r e d h e t f i s i l l a u q m ? r o g f n r i e n p n r l a e p t a t y e i r l t t a a u e q h d e e c h t n s a v e o d a D o t t p n e u r s r ’ u A c E g ? n g M t i n F c i P l e s s t f e a r e o c e r r t d t n p a e a e h t a e d r A n r o e i b t s m e u u Q N 1 . 1 2 . 1 3 . 1 18 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 e t a n s i d o i e d e e t c D m A m I t n e m s s e s s A t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S y r o t t o c a N f s i t a S y r o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R , s . f a e d o h t f e n i f a o i l n t r t n P i o r o y e t e e t t e a l l b y l a b l b d l s r n r d l p a i a n f a l u o l u u n h d d o l r o s r e a o i p a s t n e t o h e t a s t v l c t i A e n c y t a i n u . d b n e r h i o e a s , u n h f p c i e i d f w s e l t d c a d e l C l e o t k A i c h n a r a l e e n t t e d r n r E f e e c m m c s h b o u a e a l , r e o e h e f e r p e e u s p p t t d s h s e f f o s o i a r t a a l s w M - s t s i m T r e r F t s n e s , r a s s s t c i o d u i n s n s c a e r g v n a P r s i e s p o e p e n e e s s r t t c y m t i d o d n n c i o e c h i r m e c d t i c n a e c p e d r r o n m i c r u m e e o u a e o e e s , e w p a r o u m l r n p t o d u t i c h c h t P b t f q a t n s a e e I e r i n l , s e q r a n r s l n d s l n l e a h t b . p o l e c u e l b s , i a t r i h l a i a p l p a l i c s s f l h h u e a e t w t y s m d h P t s a e a s v s c t r t y s a s d t n i n . s l r e h a e f a i r t c s e e s h n i e o a s m o t r c e d 0 . s t e t e i d n u u c d r i t r c l t s y p s n o . a e h m p c d a a d s e 4 n t s n n e e i t o e r a d i u o n c d p n n b w c h r a s r o s l s n t o n a h l a P t h o i t o t o l , o s a d e p n i a i l s a C l c r i z d r a d a t h n z o a n d s 0 i P p l a c , c t o n c n i d l o e l a r e i h a . n t n s n e z a s l d n t o s n o t r i y r a t t n f i 3 a n t a d , P t e i o n t a u e e g e r . n l r o l a , f s r m n s s a l t s s m s e e g s t o o i a c a i e s s e n z d l o m o l o o a n s a t i n r i o r c u e p e e m h r e i e r C r C f o r o r c a i r t o t r e n m c d t u t t p n c e u c e t e r d e f n i i y c s e s g o q r o p a h o h o h a d h e h p s n r e r d e e T d t c T p w a s k t A o C a i S o d S p a r S n o i t s e u Q l g o i n r t n t c o l e ? g c f n e i s r s s s s e c n a e c o l r o p p r t p p a u t e o n r t t e t e r a t r e a u h d c e d r A n a n r o e i b t s m e u u Q N 4 . 1 19 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i o d i e d e e t c D m A m I t n e m s s e s s A t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S y r o t t c o a N f s i t a S y r o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R d n a d e w e r l l e d l y c n t b , d d . b e , h a o h n i , t l i n a o n e n l v o a n a l s d h l a r e e c n d d i o a s u s r o w f s e e i s h e t t h e s u e h e n e t r n d o f w i o p n e a h o s f u S r s a v b u e o e p o o n o h , a a z o i t b n r e r . a i h i t i i h e t l d h t h a g r m t e i o r f c s s b n d o t t u b r n s i r o a s s z n o l s t s o a i c s a h e e n b u a a t a i e g e n i a e T e s f e r , h l r r , p F i d z m b h d . c r r m s i n s a r , , u e o d t t e s c o s r o d s w c e i o k r d a e e o r g f t l o n n a u d t r c n n t o t a s i p u p s h r e g u a e l u e t o o i e s q s e a t h s d o i v n s l n t i c m o t m r c v r n i l e e e s e p s r n b e h e a v d w h a e i e o d a a i u a r r r M t d z l e r r a g t h m h i a a T f e n s y s c l i o t t u h y e s i l . e o a n e a n n u s c a n h n d r a e r d m e i e t q t , t i c w e s d l e o o l k e i t i e g l n b r o o t t t n r i u r d a m a a t d i s a i b m d i e a t a n e o t r i e r t s d o n d e s c r a u s f e c c a w y e f i h i v G e e o s o l c a r i n u i s p n t f s t t f i c u o o , t i o m t e , h h a t c e i c l t n g s n k a o d n t o n a p w l i t a e e r e M T e i o i n o u i n t i o e s t u e r o h s s h p . r t r s d d a t s t e e a t s s p s e T r u u t a e a i n n a w d d e e h t c d n S l e - r s s s n n e w e s n d m e m o s e d l n e d i t o A n i s r a n n e y e c e e r , r e g a i n n r r f o t a d l a a t w o o a h t v x m n o m a G h b a u h e s d s , o e e e e t i e r c i n e e o r t r s r a l y o l d o A w I C u t o d r s l r h r t p r y e t o i e e t z p e t f n h y . s r s l A e s a a a d l t g y n m h h l l n i m m t t a i n e e d t d , e i n t e s n o i s v h n k m c d u a e a a d t e d v n e n t E i i s w w e t a m t a m A a r o n d h i m h r g n u o o l e s o n a t i e w d n C T s o a c h h r a T u h s a s i l S D p a i i t n o i t s e u Q , d d n s r o M T n a n F a S o d t , . ? A d e i r t e , a r l e a f c b l o l i G s e i l a A F r y I c i , r t e a A s h a p v ; r C e s a E t o r r t e d A o l t d n S M m a e c a l i e n : t e r a a h e n l l D l r e p e e r a f n r m e e u a e r r c x G A E n r o e i b t s m e u u Q N 5 . 1 , f s s y s o f l . e i e g h l t l o n c a t r c r m i n c t t u h n r o o e g y f d d c e S n s e o p i i s t s , s c . y h c n e e s t a e w t s n r e t e h t a e d y s r e s t a e o h c n l a t b i e b u f , e v p r o s e o t s , d c r r l f r a s d d e o w k a t . p e e s e o e a r a t e e t r g n n s n i p y u s g s p r e f i f n e e a p e t e i n v t c i n l e m o p e d i s d m e r o a a m o e e n m t d p t s h s r w r n c p u m s e i o e a i d n , u c e e l t b a c a s l o o h a y s u t d d v i n x e v i m o i i l e a t c p a r E o s t a c o h g n h s c c r c . o a r o n t i l a s s p a t a r s f i l i b l e r m l r a t h s c o e o m c e h l e a c e e j i o t n l s s a r , n l r e p s , r e d o d s r r u s e t o s s p l o m c t a g n e s n e e f e a e u h t o h c . s t s h n r n i o i t a n i a q i t r , s t a n r n e e c o s r i s d d r s r c o f p a o o t r p u r i t i r o g e a e e e t o t r t t e a p s o a , a a s i n t o e t v i c p e l e p z t c i i s e f i t i , p o f e n e e i h i a m m n c t s s s k p a e t a e a c e e c l s r r i e r l r v a g l c h e l e p l p a i m e a a r p h o e T s a o p t b p h o A s T w r s e s i v e t c c o a r l p l a ? s n r e o e s t f t i s r n e w i c o o t a a r p e c i r i e f c h t e s p s I 6 . 1 20 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 e t a n s i d o i e d e e t c D m A m I t n e m s s e s s A t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S y r o t t c o f a N i s t a S y r o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n o r e i b t s m e u u Q N y . e e l y y t i s f l t o i t s h t a n n b n a a h a a t a f e e e c s c s l f f a p o m n r , f l l s l a f e a o h a t e e f a y t a o t h f f n i o t h o r t o o c r a o t i d w i , i n n l a p u n m g d e g e s s d s i t e o u e c r e o r n t u n r c n r e a i t i e d l c q i o f a i c o i s h r e e n i z e a b n u t b i o i s e t u f t r n e t e d r a e e y h s s t s t o n a n h e e d c r a o n r t m a p a t i t i o r d r e e i n d l l e t o b z a a r g r r i i r i i e t s t p h d b p y r o r e j o l l c o f e a b f o l s a n m i l m m h s u x i l a i l e a h a e a i o s y r a o t e n t o n c h i e d t h a i p r t , e g b e f t l s m s i r e s c i . a t t e c r f o a t n g s h u f n f a , f a p n o d u i n o s h s t a a n I . C i a r i t t c . i e e s . d a , r i o d e e e e . p g e e s c c y s c t , h c u . e e t d , g o e m l t t i t e i t e t g n e o d s f n h i d t i a a s n r e r l e u l i p , n r i a z u r s p , a s i c w l r m p r o b c i b u e c g e e p s s t s a l u o & n r e d c e i e c p a i c y e n r p a h c p a p r , a c n t o e t n b e l e n c q . a n g r n n r e s s A a l e a p t i m n r r o n y i l b o i n p i o c r a a s t t e b r . a e m a t r e e b c h e o j u d i l e t d t c a c e g a c a m e e f r m t n d a t s h r p a e n e t t c s s i r m a u e i p h m b a e n h a a p e s u w o e o c e r l q e c n o r e d f T h a s r t a l n m n t t u p c t c . i t a e c A l o l , l s s o t a a t d n r d r q s s c p e n e h s e n a g e h r e r a . f n a o u e n n c e r e i c a m e h t y c h o s e i n u t o s e t t h h e i i u s s s i l o e i s a q i t m g m t t c s m s m t i , m l l n r a e p t i i e e & r n p a n c n u h r o b b s d e i i i b o t i s k i t a d d c u d c r f e e h d p u s t s a l f i o p t r d o o u u c r o e q u a u r e u t o e e l r q n t q h u e s p s a e c e T i y p a v p e o c s p w A e a q t p d r c t s o e y t l l n a a e d i t y i m a t i n i p h l i i r b d u o ? a e q , d l p m e d i u a r s t e b c f o s a e r e d c i l e o c o r r a r l e j o v p r n p a e r n a e e m s e f e a b t a b y H d d s u n a t s a h 7 . 1 21 e n i m r r e e o t s e m i n t o s d r d t n o l . r o m e i e t i s c r e t c a s o t v n t e r u h y o e g l p n d s a v s s e y i o n n s r e r o o r o a s g p t i s p a t c n t h e t e u n a c o c z u c f v d e a e a i c o o n i s r e h r d f i a p d l p l u n g i n l r r d o n c g o e n f o a t i i s a n h s t l f e d c u s i o h l o n a a t c o r e h i T i c t i n s s u a t . s a d m z d i s t o s l y r o r i n r s e s o n a y a p f n t r , l a e f i n g e . a a t e o l r m z n t y e a e s t a o l a a r i m m i i f a s v h e a t o d a r y d n r l p a l a a e s a s p a l T . t , v d i c s n i e s o r e a y t c o h r l o c h e t a t t c i e n f o l o h s r h a f o a e i T c e c d M h p w t , c e e l l m ? i o t a c r t a r e d e v t o s a i e t a h r t t a o t d t a e t e z c h y a e e l a r h t n d s a n e d a o n D a 8 . 1 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i o d i e d e e t c D m A m I y r o t t t c n o a e N f s i m t s a s e S s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N . s e n g e o o b l t n t i o t i o r e t i a s r h T n d o . e d t s n h i e t i r s l s i s h n r n u o o p a f a p c t o o t s f u o e e a p m h b c m d a o m a e r e 4 s t a s n d l e c 2 e a r c l a u a a d l , u a t n d f r u t s , c o r r e l n n n c r u e n s i u e f a g s f l c i l h n m e x c l o a o e e h m h t i r t e e h i i t p a s o t i w t r t g u s a w d q n i e t y t s d n r e i e o i v o s n g r e r c w v e s e l e i r t e s i u u r r . l n t o i l h v l . t a a r t t a p t a v o r c n n r e d t a h r t e m e o f n d s e i n p o e , m c t t - o a d s n o m c i e f n t s e , g o m t e t g t s d e a t s l - e e i z o t a u r m a o r n r n c a e e s e t h o a o o e t g m t r d c t t r m u a t a m c p u p e p r t t n e e e c m i i e t e h s a y a r e i t e h o o m s p M s h l o T d T d c e m h t t e g s n y i w s ? s r e g i n u v i r o e r o h t t i 4 n n e o 2 m r y m t e g a e a r e v n t e a t m a e s h I 9 . 1 , m u m i n i l m a a n t r e a t , n i s i t s c a u b d l n a o c u n . l n a a A h n S s a T n n H o o G i t s a A z t i n I n e A e a m h g s t r s g o e e i n h s s s T a u . t s d e l . u c a z t e a e i d r a t s a l l u d s o o e e a a d i r e h c e h w h i v p o c t d s i w d y d o u t d e l l e n r u e r i a n b a n i c a i f a p i i l y e l n h r i s l s i a l t d a s r r l g t e c s g h r e a u e a n h s a i c l n e c i q e a n i i e h s n d s h u y e c e e t . s s g l n c q l e l s w e b l b n u i a e r . r d e a s g d m e s h c e c e h h i e l o l e t a s r o t r o d s r o f a u g s s e p i e p s b s h l d y p s s h n d e a r c s s i a s r e i d s i t r i i a t m u r t y t o o r s m t n r i e r e s o d e h e n c t o f r i e f r c r o e s v c i e i e e e a e t h d o h t r m s n r p c s l R m e c c t e s i o w . o p a a g y a r g e r o g l s n o e c t g r n n p a o a n n t a o h r n f n i e n r i z i o a n i r s c n o a p r s s i s o s t w a f o s t c e g s c r a M m d h i o c y o e s i n e i y e t c i s o c g e t e p f i h t i u i o r s o l a s l t h n l d i a o d a r s r e t e n a a n e p t p s u e e e c s c e s i c m a l u m d q u u r r a a o r e n t n Q r e c h a e e e c l e a l l r y o c h p c e h o e n e h h h r e A p t n T c w r e t r w T h T d i t l a g s u t n n n n i s e a u m n , s a ? m A s u e n S o s m T s i n H a d e i l t a e m G n l a A p t r I e m a A t o n c s , i e g i s r n a A i b e b o d t n e c a a g ? l n d p i e n s s t i e n c e m e r o m t s p u c y r o s e d a e t z i e i r i r o s e h h t t s u a I 0 1 . 1 1 1 . 1 22 d e n a i e r l p d e i c u h l s t i c d o d . n i n y A d l a n . e s a , a n u h g o e i s i n d n t a b m w a i z l l e i e s n t a n a h v r s y r e e g s s , c r h t n o c n g n o e a e t i c h o t r m n r e p e e t o g m m l p a a u t o n c s a n g a o u r n i e l v m d c t r g n y i t o n o i l f s s a s i s n m u s s r e q e r e e l c b c d n e o o h r d o r T p a c p t n e m t r d d ? a n n s a n p a r e , e r e D s m c y s o n t i l r e t s o c a d u u d c l a Q a t n r , n e w e e t h t i n e m i s v u e r c e o o D d 2 1 . 1 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 e t a n s i o d i e d e e t c D m A m I y r o t t t c n o a e N f s i m t s a s e S s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N s g s s d n e i e s f i c e n . i m i t i o o s t c r t s p r o n e e a r t p l d z e d i n I o a a u n e f e e u . l v y c a t i r h i s n t i n g c s t t i t T v e a . n t i l r o e c e A o c a e f o h S c u h h e r s m p h T t u d o d T c H o r . a a a ) n b p e e e a a s r g n h d e o i r t f g n d o t a r f i e p e f n a d o t z f d r t i n o y t l n e b i l i l r o e a e p o a i i o t t h c m o r e n c d u s e l p q s r v e e p e e r o e n i n m d t i g t b v a p h t i l o c e e s r i m i n e n a d e h t w t l d m s t e o d a a e e e i s a h e u v n s n f i b h t t o m l i l r i i o t e n n a p t a e h c e s h o d m a ( h T c i s i s e e h l t ? b a i n t l c n e a i l d m u p e s n p n i a f i s t e n n e s o a d s c l a p s a t s e e e n h c r t o f e e m r h p o t e s v h e I o c p r a o p e c s m t i o 3 1 . 1 g n i z i r o h t o u a t l r e o n f n e o l s b r i s e . n p l a o t e i r p a t e s i e r r p a o m s r i e r p n p i e g a t a g n a n i n r a t a u M n e q y t i m n l o a u i c t i u o s Q d o e d p s h n i T a d r o m r o e e f r ? g h s a t l a t u n e i a i z r a e t t M r o a s y h t i m e l t n f i a u t o a u n n a Q e o r i e e n t i a h g s u t i q s o s e p e d i s D d 4 1 . 1 23 t t c s a u e e g d h p n , s i o d r u h o n e s ) e r n d o h r p k s i e t r e l a c s t u , c g o d r i n n , o t o u i a w o r n w d f r t r o i p e r r l a t s o f e d c e b n e - e s i v s o w t i o u e s k e s o h p s c r r l s h e p s n o e u d T i o s t t . c c w n d a n c s a e h r c t o n e h e u e e o o r c m d u b s s r m u p r o d l e r e p s i r e ( e p e p u t s d s u c a q d a e l u e e ) o h s 8 r e i c , . c r e h s n c p 2 p n T i o t r t . l n u g i - e o . p a s a e t n e t g r t i c l r e e s h S a u e a ( t b h e r t c s e r n s l t m n n o r o s e t o e s p o a p n l n t i o i n r s h e o i e l g t i a l k e s b a t g a c m r n u n p e r o p e l a i r e r r t e i r e i t a t g n w o s o u h a e n v r q e e r l o T a t i p e s g o f k e r h o t t a g h w t n i r o t l t o l e e a e s n t r e b a n t ? r l o i s u r s a s d a e e v e h e a c p c s t e r o o n h r a t p p i o r e e e t n r c t t f i u e r a e h e t t d s s i n h I 5 1 . 1 e l h g l a t l l n , h d l i a l a n h n s s i , a s h e c h a s s r e e e d t a t y b e n e g n e l o e y n e r i l i o n e o l a m f i y p l a t r a o m p h e s r l e m s s g t t p l a n e e m l e n e p c e e A y n y a m u r . o M e w e s r a e l r d n d p i o . l i i o o u l v i v m g p e o n q f o t e i r a m r n r p e t d e i e r e l p t e h r a n o a o d n t t o g i n . h n e g e t a i s g a n o d i h m t i n p u c g e n t i w f f i s o a u c o l n i o s o e t e k a o h c s a r u s d r t D z a s q n d i t b . d e a d n a d e n e , a a e i e g h e g h n i n n v t n e r i a t i o b t e i o l l d a r i n c i n t u t a l c o e r e f c e a f s h o n f e n u l T f i b m e d f a g t n a e i d i h r v o o f r p g ? t n g n i n t n i e i a a m t r e e t r g e a e y n o a l m p m s e I 6 1 . 1 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i o d i e d e e t c D m A m I y r o t t t c n o a e N f s i m t s a s e S s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N r o ) . f l e f l y e n n o y i i t n t n t i l i o n a e n o i z b s d i d r s i r n s e l n n p l e a o a a p r g o p t d e h o t s n s ) i p e e f e i t e l u r l I h m a . k t b a e c a s l u n a y i n g q o b b a i a ( v a n e t i d a t y e c r n a h t n i y . n i l a m d u a f i f d d s m y n n e a l k e a h d e e c o s u m a l n c s r i h a o s e a e t s ( s t i b l a n g c r m d s l t o i n n o n n a a i o h t a y u f i t f r y t a i f c s n z t y e i x e r p r a n i n n e u r o y i a m f t m s a g d i i r y a e r v x m p e m g o i r r e o h k s a e t t i n h a p u h o e h a T m s w b h t T m - l t s o r s d s a d e k s h t r d s i o n c n t a p f h s e s T a e e z s , n e e a r i , c i c l y . o r , o c ) . t s e c s o t n t e s o a o t l m c n m a e r r n a l - e m p m d n a a n d r p i o h e e P o l a r e e j e t t l e b e y t t p t e n t l e e a s r e b d g m n b o n e z s o n a d h o i n o o l t y t e k i s c e r n r h s t a r n e c i l i p a m p a m r e f a c m s o d p o g o t o i a i p t a u f d s m e e r c 1 t e e r u r c c r n u i q g t o n o o p t s q o v t c n m r i p e n , t d r n e a a e p e d i o a o l E e u r p n r q t i l n e e a g h o u . r l m r e e e c o o q o d t i u v e e e c t o t l r n f e r e s t r s c y r n e n e v p b d e t e i y a n r e r r S t a g a o p a e b i h w , t m n h e d e l e s n o d l m o a e t l c i e l y e r v e r u b d t u s a e f t i t i f a n i o l e h t n r , i a o ( h t c v a c . h n n t s e o o g b p e s - n s t i s e e a r f . a o v e r n o a i p l s c o f i t d n t e f p a e p d r o c u t d i e n f , a o i b e f o l a n a b a i e a c a p n r i t a s l z d r o e l a t a a l , i p a e h a h s m r o n e u f z m ( t h c t c a i h n d g t s r a F n e e s y u e t o . d g n f n e s n v e a m v r a i . n r o d e r . a o g t m n s a m e r d m l n t u o ) r n m a h s t e s h l o e a d e r e n a t p e o e i p r t s r e l n e b n m e k n a e h v u g i u g h t l i p e e a o a o r o a s o c y b a s h r o a q r s h r m e r i w b p s b T M a T p e p m a s p m C t x y i r r y t o b a i s y r m e v d ? l e y k e e t i m l p l r i a u o n n b s f i r o s t s a d e r n h n p e o t a p p e t r e s r n a d e u e i r s e s f l m n i a n e e i o a e u g t r t c q e o a n h t n u a s m f I s g e I v ? i n t ? i e c m i v m e d i a t a b e r n r a r g e t o v g r o a p e r d a p r p p e e m e c c r n a c n o a n a f e r a n t n e n e o t e h e t d n t t n i i e n s I i z a a a i l i m m m t u 7 1 . 1 8 1 . 1 24 n o a t i c n i e u a h t d t n e r o i a r p m u s e z d n i n l e m a l i n a i p h o s m l e d t v o e n s a t d r l t l s a i a l p h s h s t c r r u e a t p s a e f e r o s . r t a y n t p t i l o a s b i i e l a t h a l p u c i e i i a r s h t r v i T c a d t r l e a b p l a n r e i o e r a t t a v i a p a c e u ? r s t s d s T l r o n t a r c a o a t i p p i t e i e e p H r c h i z r u e a t m i s h e i t d r d n a i s e p a o d m H l n t o e v a e t s i d l 9 1 . 1 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 e t a n s i o d i e d e e t c D m A m I t n e m s s e s s A t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S y r o t t c o a N f s i t a S y r o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N y t i l i b i s n o p s e R g n i l d n a H l a i r e t a M d n a r o o l F 2 n o i t c e S . t e s s a h t t l e h t n k o a l t o n d e r r h o d n d t e t c m w d g r n e n o s i d t s a n u a u , e p e a i c s s i v l e y c n s t m o r i p i l o n t i a s e m d f e e p o h t n d l o c r l p r t s e e e a t e g e r e e a p a v r d n r i p m r h s p c r a l e a g o i s e e f e s y a m i n l s h r i p n i e t h i r e y s h v s t p o i a T t . u n d e v i o t t i g l e e . g t q s s a i n v a e a i h c s c u h v n n r e t e r t a i s s m c l v ' e o n i r l r r y f e d , p t m . b e a e a i e l e c e n g e t o h p r e h e m a . h v m h a m t t s l t d r e d r s o s , s n y o e a p o a T t t s t p d e . e s e t s u s i e s t s e o l a e n d i u q t h t u r t e s i m p c x c c n i s s d a t e t d n o a l e e a e i t l a e c l e r f s t g r e t h r a e m d t r o a m o e e n a i n t t e u e h c . v t o c a s e t r i a a b c r n p h h e o d s S l o t y T e m t e t n d . l i c e . e e e c e a e l t o t n n t s p c r i t e i c t i n e r h a o s i n i n e n c a a t n e u h a i a a e i c e s p q e t o h t c r a , e e t t i i s r f m l s e a m u p r r m e r i t v r s f r t c t i t d r p u c e o e t c m d e p f e t s n o o c o c i e a e f s h e o r o o r i a e u t n D c o n d p d T c r I d i h h t i o e s t h r a t ' h t e s e m ? h e e t h t o s r t u i n t c s n s u e a n d c m e r e m e u y e m h c t t o i l i t n e n d c e t s o a a y g f n t s n i e a g o p i h t d i p n t i a s e i v m h s e h t e r o c f o D r e i n 1 . 2 25 . l l l s y t a i a d i o t h e l l d s r n f i n e i c d n n t t o o e o i f a p a c a f e t N u g d a . d d m p d e i c i n h e . l i i y h o l f i i x t s e f i s r t s r n t r m t p A a n m i . n e e e r h o e c d d l o d d i n f o e f e c i o t i r i h e r i d r g w r e l p y i s t n e i g a p r t n n n n i n s r e a a i e a s i f e a r e s g e a l t r d d i d t e e a d s c t n d t n c t o e a a n a o s r n b c r c o e , a i o l h p d t t i d t s d l d a s n c n a e a e e t e d h r h a e a n t t o c a a t s h r r e e p t r o t g i r r a o t u o c u p r n i p c a s d u o - e g d r i c n e d h i n n e o o r o g , s e f d l e i r g u p u s i e t o y t a o t o d q e l e v a e r r t r r s p l r e h e e a i r l t a u e p d o p e l m d t r b o l . e t r o h l a o e t r c p p o t i t p a a s g o l s n u a a e r e p l t e e h r P h A a u C s h b s a g s l n i e a u c i m n o d n t a c n n h a n o i c s n e d e t h o m n t l e a o g t n h s i t i e y o s l i y b f t t l a n n a e e i n o c d a a i t r e t y a l s m e r e s o u b i a f l c i n c a e t t o h r p o s f n e r ) n o s o t i ( d e r t . t o i n e t n l l p o e p l g i y m t n c i i s a l i e o . i g b v g d i o - ) n a r t s e ( p k u t h n e o T i m O l l h t i d h e e i f i t t t ? n u s s e o e d i h c g y u r o l r o p a r t e h l c t a e t d r c e t t u g a a d e o t s h r p d s n I a y t i r l a g e t t u n i o d h g ? n s a u o e s r y t s i h l t e i c b d o a e r e i n p c a a t r t n t i o a l m s I 2 . 2 3 . 2 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i o d i e d e e t c D m A m I y r o t t c o a N f s i t a S t n e m s s e s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N n g t t o c n c d a t i i u r e s e a u n o b r d t m r e d a r l a o n l o u o n g e r r i d r a f p e h l n d e p o g w g m s o , c n l o h e s n i p s c i - r o i f o e n n h l g i m t r n s o P i r a i t a u n . s i o t d r f m i n e r m o n n e f t p e o e o o t c t t i s a f a r o c n s - e r n y d m o m n d v e s r f c t o o a P o . m n e n n t s n d e o p g r i o o e v t i r i o o n t o t l p k n a c t r n m u g c A n c e t d i a . i g e e v h r t n r o n t a s p r e o e e e . s p f v p s s d r u d e n a l s o o r e e r a a d l y i f t n p h t d , l r r o d y o e n o a t l r t i t o o a o h l e a o a a t i t t r n t s i e i s e c m a n e s n t t i x i c h e t b o c m a c e f f l h i c c e t a u u t l o u e n q e d a n a s o h e t h n d r u h f s o T i c a p s d i o s o r o s - e t o s o s n h s t T s p t t e r o r . e a c ) a a t r . s r o n s r g f p p i , r u t l r x p t n o f d e e t d i a e a e v o e t i s a l a i o p c h t s k s l r s g n e i s o e r i a e p d r c n r e g e h t o e p a t n c c s t r t o a p e o r o a p r p a p h p e e d a m a e p r e r v t t o f r a r p t c e h a t f o t n e h h l y s e i n t e t s g r h a ( t t c r y r a i s e m i n p n i o a u e p s t t h u o r o r y d h t S o A n c p t e r r a r y o i . n . e s t a a s p n e p e d p n v o o h a e m t p e r s r e r i t d a i e r o v t M r e , a i n i c a p e x r . a o t f o n s p h a i i g m i i n n n n g m l l t a m t e r r i a n f n t i u n d a o m u c m a o o r f l h c o a t p o n p k o , s m i g o h d c o s u i d r l n p c d l i t r o r q / e e t a e t t n e a o t g t a n r a a / h e e g d n y c a i e r e y s r a n u t r s s t m x f t f - i e i i i s p i t d t e t t l m n r e t t c n a u p p n t a n e a e r o i e q r a a o d e e o o h h d H e t c l i t i p p f ? y t o , ) s f i a e t t e k t r s i n h i a r a r r p e r e p o d i t i e c o , d e o u r d e t t n e d p a p t a e e m h e r a r e t r e n t t t t t o i ( s n s d a y i e s s s s t r a e h t a n e a h y c p - l r e i o o d n r e o e p r p e n p h t i x r o t p a a s t r e m p I r t m i o - e t h e n o t t n t o ? a f u n m o i q t e e t c t s d n u y a e d s m r s o n e e r v p t o u o g i c d m n u e t c n i d m o e r r o r o p p v f e n e r o r A p c 4 . 2 5 . 2 26 e e t e e r t a f i a r i e e p r b d b r p o f d l n l o r p o n a a l a p e a p h h a p s g c n s i n r d a t i e i i n . y r s d u f c t i t u p e n o t r o s o d n n a e e n o l o m i t s r a d e s d t h t i a r p r t e r T h a h r t e n e t p s o a . b e f p d i c e d i , l e l r n m A s v l e f o l . r a o a u t s t t h e s i e a a n a m s n u r e h e t t i r c t e l e t a h t r a o t t e g a n e n i r t a n o r e t e i s a i l e i n m u c a h d e s e i s n t g n b m h g m a i n e a a i n t e e T i h r s t v t o a . m n s p u a i r o r r - d h r d o e c o l e l p e f r e s n p t a o a i p e c i n s i r r a a r e r e o t e p c t e n o p t p r n n i s a a d a o f f e n d o n a n m C o b i m i f ? o l a r e i e t r e f a s m r e e n t i a a i r t n p o o c r p e r p a A i n 6 . 2 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 e t a n s i o d i e d e e t c D m A m I y r o t t c o a N f s i t a S t n e m s s e s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N , n o e t i r , e c d d t u e e u i x S i f i l f c r , c n s e i e e p l s p b s e s a t e l p r T b a l m p l a f s s a x o e h c s E r . e r o . s d s r b P k e e l m c t o e e r o u t t n r h m n , f e c a r o d e f o a c e R p d e . y c g n p t s h n n a t i g e , l i d d e u e q a e b o t l , w r e n e f d e r c e t a a o a u m r l o f n c d d , r 0 u o e n . e a 3 F d f d ? e d i e f i l c r o e p t s n o g c n d i d n a a o d l e e t c n a e n m r u u c f s o I d s e e , e b , s h g l n s l t i i n . n a i o f a o e i z r h t r t e o i s t t c u c b y s l l n s n a n i l t t r s a a r u l e s n e a o t a m r e e t f t s f s e t n o h p r n r e f o a s s i d m u g r m t e i e d a s u e e w k a n l , e p i n e o r p e q l e g y r e a l n a v p o t m O t i u l i t l l i y h a d . n e g W n g a f a b s o a . t i e i n d w n o c h s t l o d n d d o i t , e o n s u t e , . d s g i n t o d n t i e g n n l c e a o e i o t t y s c l . l n i n p s r c c d a m g i n r o i o y u e e r u e e . , g e p n t d t r c n c s a c i n n s s s i g r h a n n o r g s n u r i n e e e l s e e e c e a r g d g d e t o o e r i m p e r p r g r o i s c r e b e n e r d e e a e p m r p t l d a s m a m o h t g t a o i e a e t T n n e m t , c t h l y t e . e t d f m u i g n s l n b l r e o i s m a i n n d a e e n e h o m g c m i o i n k s t n t r n f i r s d a i i s r e p i p i p e a t a t - c l r n c i i n p e i d u a e u c e n a n n h r a n q r p q c p o e e u U t t a e T s e a o c h q t n n a e n m f ? i o y e c r i t t n d n c a n u e t u e e l i n n i d v g a r f a o o e e r r c r t , p e e m s g d h w r e o n n t t o i t l n p a i n a d r n n n e g e a i n o t o m i p h i p d o l t c a i u u a a g q l e i r c r r e e n A t e g i a e m s 7 . 2 8 . 2 27 e l s . d e n s r n t a s a s e h s r a e e h e t o h h s c s o t s n c o e e e s o d e u s b h l s l c a c n b a l T o e a r y a s a . p b t i s e e n h y - l l r s t i c a a o b i c l n l a t i a u g u , h q e y t c s . o n q m s r v n r a r i e e g t t s n g e n y p i s h a c e o r t a a k s e t a c m u e y c c o n a m h a d s r o r s t t o d o g p r e o c a O t n p e d d p i . d r u h t s l n e d g e a n g c s n p a r v a i a n o d , e l p m i t a f o n i o e s i p a t e t o l a r k g e e h d n n r s a r c e e i o u v r r p a s t m p f g o e o n d r i t a p o r n s t u a p i m n f h , e f f u o o t c o g t o q c g e s g ’ e g t n n s i r k n a l a i r i l i n a k e d s e i d u t e v p c r n q a n r m e l t a c a d r e a r o o l o S n H a t h f m a s i d n y a t o t i e e l g t a a a u q r o u q t t c s e u , d d g a r n g o i l n p d i e n g r v a a e h k c s e a e h t p r p s I 9 . 2 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i o d i e d e e t c D m A m I y r o t t c o a N f s i t a S t n e m s s e s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N r n l i o e t o , l , t , g a a c r t e e l y o o i n n o t r f t r o t e t t e a l f l h a a e m e e t n i r l g v e i n i n l e c b o c h h l e o t r e n i u t s e b a i m t l v h a d l h r r n d n s t a T n e o . a a y e p p , c y h t e d e t g s s i l i e t i e s a n b l n i y c r u o a o c f p l u t i a a l o q l e a q i i e o e t a e d s d k h g n p h h a a e s i n o g T t h n s s v c i n . s c i , u n r o h p d n s o i o u o c e i k s n h t t t i p u e i e u , d g m s k c d a s i n t n i s n d e e t s e x o s h e o c n a c s c e e n n a u u i l o d r g l h . c e c o n i n g a f o u t a k i v A n n e r a e d q e r l l o l . e p d , c r o d y d y e l t e w t t w t i i u l n i e l n n i u k o n o a f d a a v u r o m l n o h u e e P a C s q d r q a s l , a t , n s d n e n s a s m i o l y e n t i o t i r n o l i l i r d t n a n v n u a n o c o c q e e g l c , n t o d e t g i v n k n i e o v r a p r l o i p c p e w u m e d d i e k r A e s n n u a o c o h f e r i , t , ( v o 0 s e o n u . c g e h 5 o r s e m i a i . t f n f e a , n b e s r t f r a o g l s s e l r r s d o u l a w n i - l n i o e i s s p e e a e t o ' r i t n e c n c e b o r h w e m o s l t r a g t r e i l r o e f s h t t o t l l P a u n e S t r t i e t , u p m e d d a h a t a t . r s o i c t r e l e h f m b f n t c t e l t e d f c s n n o o n i t d b u l o c e s u t e c a e s e a d v . a o e d t e t a r j s r i e h t s r m e o m s e m r a T e b s a t r a l t r i h s n p r a ' e n s h u s s r O b s n e p e r s u t e i s s a o P o e e a r s t i . n e t r o u t t t t . d h p d a t e i a t l i a m a r a n e t c t r a c w r e s a p P a , e p i a r e r r h c r o g s t a o a e p l n e h s h r o f s e t i n m t u . t a d t P k i e c r p s u i o o a s m w p e t o c a e a e t - m d e l t e n u t h i h e l r p t e p p c t s a f r s t c s e s u o a s r c e s s o y i m g i e h d n t t e d f o r o i c p d s t r i n r e r a a n e t p h c r m e t n f t t e a r o d o d e e e t , . a a R o a h n d e n e h h d u c o i p a n t . y s t c t , c t t t s y r e r t c e g s , e r n t c - p e a m t a n e i t p t n ) , f e e l a j h n i p d s i n e a a f t e d i l e n b t n t b e h e e r a n u i n m t u w a c u n R e a u h o g o q b a r q o a m s e a : i , o n c e c t e s p r e y t i p i i i i l c e r s l t e e n h n c r r u f s m v t i a b p n c r m c a n o o u p o o n e r u o b o q r c e a f i c f r s a m c o R f o b c l u N r o M f e b t ? t c d l a e d u m u h o o o r w e r f h e t t p a e e h o h r f t t t l f s s t a o t r t t a n a n n p i n e e m e i r m t r t m A t a e a e n d r o c t 0 1 . 2 1 1 . 2 28 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 e t a n s i o d d t i e e e c D m A m I y r o t t c o a N f s i t a S t n e m s s e s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N n o i , s , g t s i e d . t d i n s a s e m k e r n , i m l e e r e t c f h a n h e e r , r i n l o r o o t a e p d u ) o i a t r , t l y w t t e m c , a d h h d r a n P n e a e e b o e t c t n f c n n r i y t h l a o c t e a o p i b d a c r u t i e e q m r e e n t r i m l e u d f n p b c a u e p l e r e i p v n q i e o t f u e a l f d e a l i a R n m e f r a e q r c . o e h , i h t l h g e r e h ( s f g e s n c p b T , y o e g f t t s n i n . n s i l d o 0 n i s y i o n t . i n e e d i . i a l t a e t o a 5 r r g i b u h a t o a l h q t i n i f c d t s r r i i s t l i o t e i n d i n n , d w l e o g a r s m t n a e d c a o g h a b h e n s o c a e 0 s t t m c d . - l o n e a r a s c n d p n s 3 r c e c y d o n e m e a m h t , a a ' s s t s n c u i r n g , t , r n u a Q r t t s n g g a l e i n o p l . f u y r i i n , e n t i t a z t v a t a a d e a e c m n r l p i a h r e l h r e o d e f e c t o e u r , n c t n n n C n d r b t S t o a r e e o e a , s . m d r f a n u m t s s r e r e e r i o u e e q u i i p e c a q h b l k c r m i , . t u u m t e c t a u i e l e e a h l a q q h o g h e r e g . o e r e T T d a t h t T c a r t e s t s e u h , t 0 t r r l r . t a l e a f o 5 e h s h h s n u t d r s i o n o e r a r e h h c t t i t o d t e n c r e w e s r e a r a S e d t n o t r l e , o t e l i i s o e y a n t t y t l u a a l l o r e o e d b p e a s m h t s t a l T i e e n i b r d e s h o o e l s l T m n m l e a . u e . i c s b h e c m l o d i l s b o r k c e s u o s d P a e p n n c p S n h i o i i o . i o l i c d t a t s t p r f t u s l u p e o n l n i f a e e o e y t c o f s o s f i , a c o e r m R e d . n p e e v v d i i s e r t l n n u a t n g o q n n o a t i e i e t r s e t r t v v n e r e a e u f v l a r r e r o a o r o P p t p c h s f d n a m e d , t s e y t s n ? g e d n m l e i h u c r o c o t n n e d , o u d q e c e r o h t t i s n I o m t d s ? u n e r a l r d b e e a c h r i t t o l o i p r n p o o a l i m f i o e d e i e l v l l b t o u n r l e t o v n s e o s r I p c 2 1 . 2 3 1 . 2 29 r g n e o n e o p t i r h s d r o t r e t e t i n e f y r f p n e o s r y e o R t i t b m i o , e n . m a l o . g o s r s f g . a e t e s d e m l u g e , n e b t a . a o p l s b T m a r M 9 . l n t l s o e . 1 m g e g a s r i n h C l a s l o i o s e e a m a t c . a d s r o 0 . d r t s r e a a u e P 3 n A t a t . p d e i n n r Q o s s n i o m t s t r a d c r m e e e r e e i m c r a p f a a e i l o h d p c S r r i a , c r l e s e u p p o p e h i r e i i q t l t r u s e h t b r n s a w t s q e o e T t n f y r c i o i c s n i r a s e t s g i n e s s m a v i n w e e e c l p i l f e c u c i a i i r a i o q o u i e v r e r q e h t r n r P f P e v s i r e i n l p d o d e ? r t r e i s n o f i l a o c b i e c t n p a s s o s T e m s s c s i e s o r c e r e n c p t o e e r e m u P r A r a q e r a f p 4 1 . 2 r e f e e R b . l s l a a l h s b a s T e s i s c e . n e c 0 . u r o 4 q P n e r n i o F i t c t d s i e e S e f T i , c s l e a p l a n b i F s a s T / a s s d s s e e e c r m c o o r o r f P P - r e n p t o I t s ? s s a a e l T d b l e a a m T n r s i o s F f / r e c s e o s p r s P e c e o i c n r n i P - e d e n u i I q f i c e e r r e A F p s 5 1 . 2 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i d o i e d e e t c D m A m I y r o t t o c a N f s i t a S t n e m s s e s s y A r t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E y E c A n . e n S d , a T e u t s r e s S t n q e e e o e f r I p T h e t N m r . r r b , l u f o d e s S p o a c , e d I l a o i d f r i J h 0 d . e a h r c , s d 1 e t a d O t s n n v r n u s l b S a I u a i o e l i t , t b r , s d a s d c l a N r e e e l / c i c d E v S a d f i h n n , e c a o r o , s i t i p s t f i e I t s N p e a p l n r s D e r e v r - s , b a b i , a m e e u l s M a d T p b m n i T / c e s e u l o s S n w s q l a t s n A i e e o i e h c u o y t v o t s s t c c b a e r r . c e e e i t n l d f s y P e l b l t e i r l o k c m b t c a a h e a u p i c i c i s V n r e l l l d i e h . r p p b c c o u e f r e f q p p u t t n R P e a a p e i o e c n a d i u G d n a s t n e m e r i u q e R t n e m p i u q ? e t d e i s f i e t r t e c v u d o r p s I n o i t s e u Q n r o e i b t s m e u u Q N 30 6 1 . 2 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 e t a n s i d o i e d e e t c D m A m I t n e m s s e s s A t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S y r o t t c o f a N i s t a S y r o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n o r e i b t s m e u u Q N t n e m p i u q , e n e r i , r E h d r s u d u d l c n t t e o - n a t e e b n s a h r i a r c e i s f a t o i 3 e s . e n p l e i u l c T a s p 0 c q o e m s . e r n d o p s b r m u e a 1 r s s i l o t e q t . n p r i t , , t c o e a e t n a n o c a c e s n e t i , c d l o c r o , c h s s u w t t u r t i n e o f g o e P s l l a i s e e e c f S o r S t i s m a e n s t c i n t l r g y , s o s a a l e r a l e g n p l , g n e r e t a b p n i n l g i a , e m i o d s p u o T a o l s p e x c g s c r E n e n i w i a p . c e e h n t r v n d c r o m n / u a l e f h e i a t e P t l m t s e a a i y u p n q l e s e r h u t g d b t a s q o n c t n a i l a s e p i r p e m d n t o l o p h e e b o i t r a e t t a r n l o n e h s y a e T s r c m o c h t p o a b i a i t c u a d i q l e c k p e i f i r c p o . t r e f s e h a , l e e 0 c c h . b t d e 2 a n b t o d t a l r e n n a f m a t i o h e i e 0 t s . a t n R r n . 1 i o b i e l s t s n l a a m a c o f i c i i p r v t i t e u t c e r h q n e e T e i S c e v e t i b l e l n l a e v b h a e s r i c s p l e a p p b o a u t t e n e t c h o i n t a t o c i r e l . t p f e 0 o . m e 2 r o p c R n d . o n i n e t i a d l u c e s e d e S e c h l , a c s p l u p s l e o e c r e c b o r n a m o a T r e n e d e t s e e h t k c n c e e i o h h a r T c m P d r ? n e t a p n o e , r s p m r o e i p t v u a a r e h q e n s l e r o g m t , e n s t s o e c y c a s s s n h r c e u n c f o o e u r D q p n ? o t i n t t e n a r c r e f i u m i c p r e d i v n u r q o a e / , d s d e s n e a t s c s o o n p r o , p t i d e r a i e r f i A b i l t r a c e c r ? s o l e d & e b a s k c T e e l p h s s u e o c c s o c e o b r m t u P r r e n e h p t i o d e t c e r e c A t a o l r p p r e 1 . 3 2 . 3 31 3 . 3 d e e r t s i a c h u t y s 5 s r r d s n a 1 . n e o e t . 5 o c t i d o s . r e c r o c n r 3 , . l e t u e P u u g i f D b d d . o 0 r a l l e r e e e r 5 e a b y w s , p 7 p . h a c l o n r e 2 m l e s i c n l g t u S t e b a i s l i e p t s y p u o e r a M e s s e A r v a q d e e o r e n p r h e r p e u h f r e e t c m p w o s t e a a e s n y n h D n t t s t d i i r T 0 c o e c e s u . m t 0 5 f r e a r r h . 7 i i t r n a o n f e 2 s i 2 n d e a e f u i e n m n S t m r d r u r e d o e t i M u s f o u e i l r u t c A C e e t c t s . e u q e t t l n y e S i n r t a r b t i r p e , e d a e e s e m s a t m r p h e w u t m p t l r e e f o m r b l c t o t i o c e e a o e l c n T p T a d r A a u y t i r s s m e r p e c o f o i d r n e P u r m n ? e f s o i r s l e r u t e t b n a p e a r e s m T p y e r m e v i u e r t q u e S e r A R 4 . 3 . e l l c y a a p n h r s p a f u e e t r l o s l u b o t a n u r a c s o t r i n l e u o e n i p p o t c - m p d n e e a i s o c t e h c a t h e n t T n r i n . n 0 o u o i f p d . z e t i t e 2 h e l t s i n n u o f i n e e t m e h c e t d e f a s S w d t t i o n , e m s e b a i l e l n e e b n l o p h a o z i t u t T t a o s i n r c i s f r o h s i a i e v m t e c h w o e r t e e r h h o T t b P t e m s c o s a f r e n c r e e o u l h r f p t P e u n e h i t o c h t ? f o t h e o m i l n b w i n r t s a o e i n t i t h n T a t o i p e r t a d m e e e v l l r o s i e t r u h t n q e s o I c r 5 . 3 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i o d i e d e e t c D m A m I y r o t t c o a N f s i t a S t n e m s s e s s A y r t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n o r e i t s b m e u u Q N l l a a h , h s m s t s u s a r m i m k e c r l a i n e t t a m h a e c e s a e h e t s f h a e o T l y h t . r s s i e T . l t d m r a r i a l u a u e v l q b e a a d r h t n e r l e t o s r a m e h p t i a s i y l p . r u t e d e q n r t e e a e y t e d d n n r n n t a e a e t r m a s p e u e t e s d f c h e a d o n d c i e o h r e n e T p b a b r e y m y k . e r f i g h t e a c w e r t t n f e i a o o r o t b v s u D l n l h f l l y s s e o l t i s d 0 5 t o h e a a l ’ r o r d r l p n t r t n e a e i 7 d t h h o t n r o y i a n a s c o r c 2 s t , a f t b h o e d f o x e r n r l r d s e , l c f e d o S s e e e o o t s n i r a u c 0 a t u c s c . a . c d u M c o , e 3 t r t i e s l e e a u s a s s t s c r A b n t g e r e a r r e e e u d p u a i s c r d e r e y i s e h u n l n l u o e s e i a r e i m u s n e n o q r p r h d h t a d a f n r n l o t a d t e n t t p e e e a p r h e o r u o e e t n 0 u a e s h c s c n e . n a s f h r b r h s h t h o t , r o o o 1 a i e t r i a p ” r f T e , d t r s s m t s p m s g n n e s o c y o r m b c e s o . t t F s l n i e l a n l r d a l l y i o i n a h c . e e o t m e e e a o t v r a l u t i i g o n e p p r a a l a g d t q c d s a r m r c h r i n i c n d u n o h t e i n e s i e o r e r a t t r e t r w u r o S o n d t t f r n n a s S n e t m f t e n o i n o d c e i r o h u i o t t y l i i i , / r i t o u o m h 1 b n l a e n e r t q d e g p c s f r s e o a e f p o i d k o m p a I u d e r n T l d p t e a a m e o u . s n n r a . b c m t n w u n n , a h d , r q e n a e , e a g s t e a e e a e h P e r s s d v m l r d i u o r a d t T i n t , “ d e h d t / n d o l n t o o t a r e o n a s 2 a h f r e c t p z u p t a t i o e s e . e p o o f e s l s i a a l r r i n n c 4 t m e r o a r s s t f u o t e n i u t o r i r r c t u c e t 1 u o e r e n c o b n t n b . n n o n s e r e t n r 5 m t o e e o o o r r o . n t a h e n e o u 3 G p m d P a c C a c g r c f e a r m t p o c t r o n e d r e i t m a s p e p i e u t r q g y e i n n ? e a d & b l s r e i u s k s t f b e a r c c r e o e o r p h c l y e m r h e t r t a r e l r a a A u q ? e l c y y d e s l t a l n u a n r o c i e u u t f m n a u i d m c n t n o o a o t d s c u r d s o e a , n t a a r r e d e , e h r d o n p e t i l s e o n l o g o r e t m m t r n a o A c 6 . 3 7 . 3 32 , r s s k e t n e v c o h a s a t i a o s n g n l t p h ) n s o i p l l t u e R s r a o o I t t t r a i n i m u f ( f o n e n h i h i o d n t s n o a l s o r p s t 0 e o . , n i s r m i a c t e b w i s a 3 r e o s r l . l t e t a a s c n f h a n c t r e c d l y d o i n e e h c e S e r e a n l s t n t o i t a l i t a n n , a h a i a l m p d c e - A e g s h e n f s t s n t h i n l e a o i a o l e s b i c e k p g y r e h c m m r b s , o a a m e o e l / e t T c p . a s T c t o t . h u s s s s x n r c y t s a e e n s f E t s s i r r a n i e b e o e c o e u o t . i o h l o r c n c p t n s r e d d i s T t p r o e o e e o u w e . m r h r n e a c t p t c n P q o e d e o e w r c g e r e e h r r e e f p r e a p m e i r , r e y x S n s e p l p w d a e / o h h e a l l . t o i b h o n u s a a m p t r - t s i i t c n p i a s a s i e k r s a o n t c c n o o h l y i a e t n b c b i e m h i t a f r c r t m i e h t r o l t u n e T a w o a p e a c a s a v CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 e t a n s i o d i e d e e t c D m A m I y r o t t c o a N f s i t a S t n e m s s e s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q g n i . t l . e a l s s a i a t o g r d c u e . l e n t u n d n p o y r i o g u h g o h s c c i r b e n i n t t n n t i d i n n t i c h c a d r h e h e a e o n f e d e a m d m e i t s e a r o a i i m i c r e t a l i l h p c e e r h e t c c b l o a h w t e t e , e e h t o r n t r a p e r s l 1 h p e f e a r h c y d l i p s . i f e t o l a r t p u e h e i - t s e l s s l a t r n o i n s r t k a o t a n t , i l l r l t a a e e d p e n o o r o ) d l e n b t k g o n o c e n i c g t r r h s o o m c r e i p c e a u n t t r h t a e r r e u p t t a r e b b e r n i i T e y i r n t a w o b l o m t o o t t d l i o o n h s n h c r i t f l e l a d l n p c r c p c i e e p a f - i a n a s d n r r w e u n a r s l m e n / - e a h h e o i y o e o y m e o d o l l T r r o h s c n o l k a h k s a . i t r c e p t t c i c s o , t e n u m a n a i p a n t a n s g r c b r g a i n a o e s r e i l v u n e n o a i i a i P i c g h o r e t c h p q l m h n f g r i e b r s e l t u d i e e a / t c t t e i n d o d a t p h i l d l a t i r e m t o e a r e o t h h n r e t n w c t p o d e t w i r e e c t i e p t o o t n h h r t r i o a i v a a c t s e f e s d o r n l g n n w n t e e i u a t o c d v p r c p o e r o o r n l u c o u s s / r l l a n o s b t r g n e d n c l e d p i e b t o t n s e i a m w i n r o o a r r i s t e n l t p a n a r k o t e a e o a o a p t e a c o r t w a o e s s a m n r e a h c i t d t z i l n h r s m c e e r t e s n w r l s a d e l p d s c , b y t e i s t e r e d t e i t d e r e a k a g t y h g r u r n h e o a n i e c a r - a e m n c a n / e a T t t d e i e p h k b n n e / e o n i n l n t a o r u h a o e e h . i e z h s c g h s i t h s n r e d s h a o s p i e r r h m l m g n i p i i p r t a n p i s r l f s w s b o e b s b e p e t s i r i n e i i e o u n i b n b l s m a o c e s t e u a o p d w n e r i g w t e o t s b a b r t a e d i r h a e h a j t m e a t a t a h - e o m s a m h h e h a e h d a t p r s t e l o C S 3 D H c t e t e b r T c W a e ( T r a s s T t T a e a h t r p p • • • • • s e t e t o e n e n h o o i r i t i n h e d t h t r d t h a f o t d c e i o o p o e h i f r w i i t w n h w h p t r e e o s e e h t s e e t i t a o m d v p l i m d / a m l e s r e i l l m l p o t o h o a e r l r u r t i r s t - m o d t i r a l k c e n n g n o c t e o b a r o c n t a h i a e o s c o s r c t s b h i y p i a r y e l e b , e a e t r e a r a n ) h g b t f o g t o m m b i n n i s i n k a e r o r d b e c t - p r p a h e o r e ( c a r e e a h h r W c n p c t n r o e i b t s m e u u Q N 8 . 3 33 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i o d d t i e e e c D m A m I y r o t t c o a N f s i t a S t n e m s s e s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N . e y e e r s b a i r d e i s t l a a i l h s e e f n h a n " e . a r n e " T s i p a r e t o T t s a o f o l p l a y h . t i s h a l i m t e m n a g s i d g i u a m e a o n e o h m l - t o e n i n q i e n a i n y r a i a s h i h o r e f l a m n e a e o f n t n l " i m e v w c i i i s a h g f n e n m t t i b l o l r n e b a i m a l a h o e a n o n s i d a i l v T ( - a r t g e u n m n a a e . g a / o e a s e n y a n i n e h g h r e o s r e a y e i r r c i n r e n m t g h e i m u p a s h o f m e i a m i i y a t m h r q e r n d e r f e d w m s t t t e i c a e e i c S e r b w a n / f u b e e a r v e . d o v d l a n n o l h d g l o ) p l n h n r . a a o s a d n b i a a i s e s u h r s v w v t n f t l n y s t o a n t - t i " l r e t l c a n a f i t o o e s o c a t e e l c c g r m n e r m n o s e e f e h m v b n e n r e V s n r e i s d e e a p t m o h c e n n o t o f p s n e r i o n o r t n g a a t e o t i c N h i e f l s o g a i c s c e d n r i p s . g v i a t i a d u e o t a e n t e i i s i n e m r m S o d n i l s e - t n k e p a s d l n n r c e i n e u n e o c t h o t a e r a e o h t u k i n s . t e s m i g s F m c u s y k e s c n y s s s i n l n n a s e u i p s s a b e u o o e t m q t i t l c d o a h e n c q m c c a i v o n l l t n n o A m i s r o e g e m l i e o a r a e e r t r b A A w v t c p • a d p t • v V D • a a r 3 d o g n r , n s l m . a e i e z n a u n t i c e s g g d s t e a s m g i o r n g i e n e e i t a x b i i o r n i n d p i l o u c m i r l m s d u a l s f r o l n q t a a e p s a i a a e a t u h h t e d m c n l e r t a s m r o a b / , c e g k e m m r d r a i i s i n o a o p a r t n f e o t r y o t r t o s a e t a e f h t n f a i s p r i c b e i a e r d e g t o n n i c n h e l i n o o i p d e f n a r u o i n p m s . m f e h u . t e t m t s t s a n u s m b o s u c t m r i o o a r a n n t o i f a n e a a i s d d h p o n g o t a n a t c e l t e e r v g m u i r p s d r i a d e a o n m t b s l t u u n m i b s - e n h g q s a e c s a a a k e a n r i e i o s s e r e g c h c r i n l z t p d c i i p a r i m o o p e d o t y o t t r f i p h i n i a a i a x c t d p c a T o t n e n e u t e c o t r o r o a t o e s . s u i p r s r m t m e n c r s s t i r u d r l o t o i o m a h a o r e m h t u l r o T p h p A h a o b a p n - t l r s n c a u r u t u d ? e o b o i m h r a l 3 g n n p a f i o g z m o d i i n m s m i s m x d o s a n u m n e c g a i o i n n a r s i r r r p i e m f o o u n a t q e s d r r e t s i t e i o t a , r o f t s a c p n r r o t o a l F p a u o e v l s k a e c v ? m n i e e i l u r e t q s a i h h t y n s o t i a t n m w r e m d o v s e a e t l p c f p i e a a u n s e q n l i r a A e o f c s i d 0 1 . 3 9 . 3 34 w s o ' l r t f e d u r t p o s a n t r e a u s e t r g o e t ( e t n i p s o m a n e r e c a b o h t s d e l a w n e C l r a a h e l o s t . h n f e r m s e e p e a s g v p r r e d a o d g u o d n h c s e r a l w i c p e a o r v e c s h l e c o c s F e s n r p a ) . a s s l y n l n a y r e e b u g s a t f a i c i t n m e n g d a e r . o m s e e l i s d a r a h t m r a e e - t p s f s u o p i v r e n o j e t s b n r e m d r m t a e l e v e u a / t a e p c l m e h o o l i r r r m s p p d A t l s l a e w r c o l a f f o n s r u e f v r e a t e h e r e s m ? s h r o w e p t s s a l o a o r f g m e n r t a e o l g s l a d e p o n o D a c s 1 1 . 3 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 e t a n s i o d i e d e e t c D m A m I y r o t t c o a N f s i t a S t n e m s s e s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N e . l l d t g b a i e a n l h f a i s t d i h r o s r e n r e n s d t i i c u m u r e n t t e d q s r r u r a n n e e e l i t a ) a h r a o r d h R c p c ( I m e e a n e t r . a r n u r p d u p e u e i r t r l s s e i u f m d o r r r f a e t e u s a i e t d l r e c e t r n n a e e e t o p a b f n m l e h b i I n l m s n m r l . a c c s o e u a o f h d t e e r y u m t e a b c e e s p o g u o h h s g l y l n n t T t t e t a a i r l l o a h . f n s u n o u u r t o e t s ) s t s e a n a c n r F e a n s t r n a 0 R d a e i e f t p 5 . s a p o e s y d s m e ( r e l e l m d f a r a a s t e n u C t u u a g i t e d t v 8 r o t a 2 r a u b d t e r i h t e i x d e i n l g n r n e a i e i e a p p t a c l s v e h r n t f e r m m o e l r e i n h e w t e c b A p I t h t t l l d d a e n ? e s s s r r e a e e a f c a c l r e a , a g n r g n s n t i r r r a e f u u h g d n t n h c f e l i s a i s g t n e h s i s b t a r d n i t f o t e s a w d u p s d r e o d n r a d u e o t h a i i e n p p t e t e i c e r n u e m h h t t o o q p f r c e s r y o o n p i F , n n i o i t y a , r . t z s t s i l e l a i r u b s e m b a r n h a T i c c s . , g t e s s g i l d e k n n i n a t c c s z r e o i e r d e a r u r h p P h c t b a r e f r h o l o a l k c , b c r y a e h a o t c h t c n r a i t l i u l c b p e n e l t - n a l p u c i a a q t d h e i s s e f r r r n r g h a t r e e , n f g t i o f a t z t o o i t n r , e i i r r t e 0 e e n f . l 3 e e b p t t a s R n a e m c e h u . i o i l y t l p t e a c s h e i p u e a A a T h t d S e h h t t a n b i t l ? y r a t s d s g e i r o m n t i e i z i h i n c t n o t l t e m a s s u s a I 2 1 . 3 3 1 . 3 35 g , l e . n t l h i d a t h n l e e h t r y c t e b s o b n n e e n a s r o c e e e i c m c l e u l q r p c i n u h p t i c c t e p n a p a o e f a r i u m a d v c w e l e s r o e a e , h t h p e t o m f b l s v i u n y r c n i i l t d o c l r a a f o u d i s r h e o s c d c i i e . r f e m f d e g i 0 . t w o z i c 5 c h d e n e i r l a c e i y l v e a o p n r n w a e e r e p n o s i o h l u i c t l s c v c q e i s a a , . a e a e r h h , S i m g . n s u T d h e e t r i , i , e . o s b r e d s t y l t l t e a m b a l a e c r a i t b h . a e m t r h r a c d e s n T t e t e s t r g i n f i r e t i n i s t c e a i e a h t n s u c e s s e t e c c o e r y a e h n a c c q p t l r h e s e a t l o h a a n e h e u h a r e e T q c s P T • b h A • h t m u i d e m ? g d n i e z h y c l n a e n u a q e h t s I 4 1 . 3 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group e t a n s i o d i e d e e t c D m A m I y r o t t c o a N f s i t a S t n e m s s e s s A r y t n e m s s e s s A s s e c o r P t a e r T t a e H : s s e c o r P l a i c e p S o t c a f s i t a S A / N e e v c i t n c e e d j i b v O E e c n a d i u G d n a s t n e m e r i u q e R n o i t s e u Q n r o e i b t s m e u u Q N y l a c i s t a s r e e m l o n m t u t o u d s a c e u i t w c e a l o d b m l e z l o a i t s r a u i o h a g h s n t n i u a h a g c e e n b n i h t h l e c . a u y n q h l b e d s a d u l e e m u Q l o n v r e a o t t r . n s y m p e v o c s o p i a t d h N a y t c . l n n a n n l e i o a c e s d u t f i e e t q r a i r c a e e e p t i h p p e i n T o s R i r o r f f e ( i y e e w g c l o r p b e n a r a t o s n e t s i p e y i e d g e h r r c c e i n t o s e a n h e s . i e c v m t i y e a i t n t g h m r . l r e i t s o l h t o v a h o c i v t r t n ) . i u u n a o c e q a o r m t e c o e , r n l g e t l f t o i r r s a u a ) . r e o t h t i o w s n a o s t d i r o n l m n e i e e g k t o h t . m i s , t a t s m y r e e e y A r a r . g s y b t u t a g r g d t p t a h a d e l n e e o i e c n r v v n n h a i g r o e ( n e r e s f t e r i p a n e n c p h o A r T f • p u s A • a r . e d t m e n e n o g e h o l t s n e a m t l n u a e d b i g c h g n l a i i r e c a a a o h s n l i i t v a o a d n c e m m g e v r l o i i g b s o f o i n l r e l c t p d a p a a a i v l e h s a r o o e h t e p c v e r h a h a t p e h t p t t o a h l l t o h e r a e c g h m v s a r n e s r o e a r f e . r f h n e e m o n c e t r u f o a l c g h n l w e i s l r n d o l e i l t a i r t C p o e e h c r a . h . e i e m c r e s n i n u s i h t e n a . l g g q i e e s e p e o s n r h y u S t i e E s T s q • s C • d • i t r a p h c a ? e d e f l o l o r t g n n o i n c o g i t i n s i o e p b e h t s I l h o c r t n a e o c r o r f e r t a e w ? e o r t t p r t r a o a e p h y g e r h t e s n e e e o h D t l i l i d o c o n a C a l i . ? o m e v m c u a e g n h t e n l i r s t p y e i s a l t h e c p n h p e e n u h e s m t u e e o q h e t g a t s h t s n r a e e o f e D m r ? c i t a m o t u a m e t s y s h c n e u q s I e v a h s ? t r p u a t p e f s o t e o e c l i h p c t a s e f r i s e o D 5 1 . 3 6 1 . 3 7 1 . 3 8 1 . 3 9 1 . 3 t . s r a , a s p h c r h c u o s a s n e , e r n s f o o l i t i a s i c d e o t r i p p u o t r , q a s r e p e s r h e t c i , . p i c o w t r p s e , t y s c t i e e t i m b e x r o d r o p o l p t a c d f o i o n h t e a s h e u c m e e A h t m 36 r o f p u t e s e c e i p t s r i f m r o f r e p l l a h s . r t s e r t a a p e f r t o t t a o e l h h e c h a T e CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 Instructions for completing the Job Audit The organi organiza zation tion is to comp complet letee a minim minimum um of one heat heat treat treat part part job audit audit during during each assess assessme ment. nt. This shou should ld be done done pref prefer erab ably ly on a part part iden identi tifi fied ed for for one one of the the cust custom omer erss requ requir irin ing g comp compli lian ance ce to this this docum document ent.. More More part part job audits audits may may be done if time time perm permits its.. Prefer Preferab ably, ly, safet safety y or critic critical al parts parts should should be audited. audited. This may not be easily easily determin determined ed with fasteners, fasteners, especia especially lly if the fastene fastenerr manufac manufacture turerr does not iden identi tify fy the the end end cust custom omer er (aut (auto o manu manufa fact ctur urer er,, tier tier one, one, etc. etc.). ). It is recomm recommen ende ded d that that the the job job audi auditt be performed performed at the end of the heat treat system assessment. assessment. The The job audi auditt is not not the the only only or main main focu focuss of the the HTSA HTSA.. The The othe otherr thre threee sect sectio ions ns on Mana Manage geme ment nt Respo Responsi nsibil bility ity and Qualit Quality y Planni Planning, ng, Floor Floor and Mater Material ial Hand Handlin ling g Respo Responsi nsibil bility ity,, and and Equipm Equipment ent are equa equally lly if not not even even more more impor importa tant nt.. The job audi auditt of one one part, part, one one heat heat proce process, ss, and one furnac furnacee is not not sufficient to use as a basis to complete the other sections of the complete HTSA. The The job job audit udit is a com complia plian nce type type audit udit/r /rev evie iew w of a spec specif ific ic part part and its its rela relate ted d pape paperw rwo ork and processing, including heat treat equipment equipment and processing records for that job from the beginning receipt of a part throug through h proce processi ssing ng in the heat heat treat treat opera operatio tion n and and inspec inspectio tion n to pack packag aging ing.. Parts Parts shall shall be take taken n from the shippi shipping ng area area at the dock or the end of the heat treat treat operat operation ion.. If an autom automoti otive ve manuf manufac actur turer' er'ss part is not available available or identifiable, identifiable, then parts from other customers requiring compliance compliance with this document shall be done. The The part part or lot lot chec checke ked d shal shalll repr repres esen entt a major major heat heat trea treatt oper operat atio ion n such such as quen quench ch and and temp temper erin ing, g, carburizin carburizing g and temperin tempering, g, inductio induction n hardenin hardening g for steel, steel, solution solution treating treating and aging of aluminum aluminum,, etc. etc. In subsequent heat treat system assessments, different parts and heat treat processes shall be checked. The specific specific heat treat process processing ing paramete parameters rs (applies (applies to 4.7 in the Job Audit) Audit) that are required required in the job audi auditt shal shalll be adde added d to the the job audit audit form. form. This This can can be done done by revie reviewin wing g the the custo custome merr speci specific ficat ation ion(s) (s),, the Cont Control rol Plan Plan,, the the PFME PFMEA, A, and and the the floor floor work work/jo /job b order. order. Each Each proc proces essi sing ng step step shall shall be review reviewed ed for proper production production records/comp records/compliance liance/inspec /inspection. tion. These steps can be compared compared to those in the Heat Treat System System Assess Assessmen mentt for the actual actual job/he job/heat at treat treat proces processs being being reviewe reviewed d for complia compliance nce.. The heat heat treat treat and furna furnace ce record recordss for for the the actua actuall time time frame frame/s /shi hift ft etc. etc. that that the job was was proc process essed ed shall shall also also be chec checke ked. d. The The actual actual furnace furnace equipm equipment ent and instrum instrument entati ation on certifi certificat cation ion shall shall be verifie verified d as being being in compli complianc ancee to the appropriate equipment requirements in the equipment section. 37 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group l i a F A / / N s s / a P ) e n c n o i e t i d i d v n o E C e v l t a i c u t j e c A b O ( e t c n n e e r m e e f r e i R u r e q o r R A e n / d o N r t i O t a ) n p e o h m S u ( c b o o D J A / N l a n r e t t n n e I m r e o r r i e u q m e o R t s u C # n o i d t s e e t . 3 . 4 . 7 1 . a u 2 . 5 l e Q 1 1 1 1 1 R A S T H : r : r : r : l : s : r a t e e e e i n d b b r m r e e o O m m t t m u u a e s r u e i s N N M t a r u : C h e r q y a c d e t i r r P t R u n t P O e a d e I r T b t o a J e H t i d u A b o J – 4 n o i t c e S 6 . 1 . 1 2 2 . 3 . 4 . 2 2 2 1 . 2 5 6 . 7 . 9 . 5 . 6 . 1 . 4 1 . 1 . 1 2 2 1 1 2 2 2 n o i t s e u Q t i d u A b o J , . y c t ? i t s l a e l a u , u s d q n e a i v c l n p i d a l n i v o r d d t a n e , i f c i w o l e , a i u v e A E q r y t M b c a F , d r t g e n n r m o i c n o n f e r a e r l A P p t e ? r h a t p e e v a h h t r y o t f i l i s c a n o f t t i a a c e i r f t i c t e a e p s h r e e h t m s o e t s o u D c t e e m o t d e ? t s t a e n r e c m r e e i r l e u v q a r e r t p r e o m h s t o a s s u I c ) . t c t r t e a e a t s , h p ( a r e e b e h n t h o t , i m u s u t a r o e n h c b i t g f i t m c a u o n u r r e n t h n d t t s i o o ? s l l , c d e a , e c i s s n r o r r i e e e a r t t p a b b i n t m u m u m a a e s n n m t r I f o e c n e d i v ? e n d o e i t t c n e p e m s u n c I o g d n e i r v i e e h t c e s I R g n ? i k d c e a i f i R t / n e g d n i i s d a t n o e L m e r e h t i u e r q e A r . w o . i n l s e r b e d t e d , e i f e s . s m s ) r i d c e r a i e t l e v c , e b v a a o , T p r r e o r s e e r p c i e p s s m e s i r f i w o t h e c t e c p e l e s o c e a p a p h c o r p i s t s c y m P r s c t e e ( r a t o o r e h t r , r f t n , e e e i n o r e 0 p . m i t u f t o e 3 a t a i r a c d p i r R n r a f e ? i o p u e i p a t d h t s t c e m s e c s i e i s p e u S L h I s t t # n o i t s e u Q 1 . 4 2 . 4 3 . 4 4 . 4 5 . 4 6 . 4 7 . 4 38 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 l i a F A / / s s N a / P ) e n c o n i e t i d d i n v o E C e v l i a t c u e t c j A b O ( e c t n n e e r m e f e r e i R u q r e o r R e n d o r i O t a ) t n p e o h m S u ( c b o o D J l a n r t e t n n I e m r e o i r r e u q m e o R t s u C # n o i t d s e e t a u l e Q R A S T H : : : : l : s : r a t e r e r e r e i n b r e m d r b e o O m m t t m s e u u a e u s N N M i r t a r r u : C h e q y c d a e t i r r P t R u n t P O e a d e I r T b o t J a e H t i d u A b o J – 4 n o i t c e S 5 1 . 2 n o i t s e u Q t i d u A b o J n : : : : o y y y y t t t t t i i i i c t t t t e n n n n p a : a : a : a : s s s s s u u u u n e e e e q q q q l l l l t r p r p r p r p c ) ) ) ) u 1 o o o o 2 3 4 m m m ( m ( a : ( a : ( a : : a : o : : y : : r c f s : y c f s : y c f s : y c f s t d t d t d n n n n p t d n n n n n n n n o o o o o e i o e i o e i o e i e ? e o e o e o e o t t t t t h u h u h u h u t n t a m t a m t a m t a n n n n e m q q q q e e e e e o c e o c e o c e o c e e i e i e i e i r r M f r M f r M f r M f m r f i r f i r f i r f i t i t i t i t i a r e i i i i u c u c u c u c t c c c i t l t l t l t l e e q t e e q t e e q t e c a u q t e e s e s e e p e s e s e e p e s e s e e p e s e s e e p q e r R T T S S R T T S S R T T S S R T T S S # n o i t s e u Q 8 . 4 39 1 . 8 . 4 2 . 8 . 4 3 . 8 . 4 4 . 8 . 4 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group l i a F A / / s s N a / P ) e n c o n i e t i d d i n v o E C e v l i a t c u e t c j A b O ( e c t n n e e r m e f e r e i R u q r e o r R e n d o r i O t a ) t n p e o h m S u ( c b o o D J l a n r t e t n n I e m r e o i r r e u q m e o R t s u C # n o i t d s e e t a u l e Q R A S T H : : : : l : s : r a t e r e r e r e i n b r e m d r b e o O m m t t m s e u u a e u s N N M i r t a r r u : C h e q y c d a e t i r r P t R u n t P O e a d e I r T b o t J a e H t i d u A b o J – 4 n o i t c e S n o i t s e u Q t i d u A b o J 4 . 2 . 3 . 4 1 . 4 . . 2 1 2 2 2 1 1 2 . 4 . 6 . 1 1 1 7 2 . 4 . 6 . 1 1 . 1 . 1 1 1 1 1 1 1 . 1 4 5 1 . 1 . 2 2 7 1 . 1 6 . 1 1 . 2 2 s p e t s s s e c o r p e t a i r p o ? r f p p f o a d e e r e n g i W s n a l s p a l , o s r p t e t s n o n c e o h i t t c n e i p s d ? n t e d i l e l n e a m r m e u f o r c r e o e W d p d e e t m h r n o i f r e d e p t s n e n o u m i t a c r o e d p ? o t / n s o n l a p e p e r t s e l o r e w r t e t n a o h W t c , d e m r o f r e p e ? r e d w e z s i r p o e t s h t l u a a n y o e i t t i d h e d a r e f I w n o ? i t a r c k i o f w i c e e r p r s o g g n i i n n s r e s e v c o o g p r e e h t r s e w o o l D l a e e h h t t t d c i e d l , f e d r e l i y f e i t t r ? a d e r c u e c s c m a a o r w n f r r e i o p e d r t a o i c s s f e e i c h t t r o r f I e c p n a y b d e n g i s l ? n a o u i t d i a c v i f i d i n t i r e c d e e r z h t i o s a h t W u a f o e e r f s r e n i a t n o c r d n o s ? a t n s c o t e i r a j a b t p o i n e n h g m t i a e t e n r r o o A f c 0 1 . 4 1 1 . 4 2 1 . 4 3 1 . 4 4 1 . 4 5 1 . 4 6 1 . 4 s e i t i l i b i s n o p s e R r o t c e p s n I r # o n r o 9 o t i . a 4 t s r e e u p Q O 40 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 l i a F A / / s s N a / P ) e n c o n i e t i d d i n v o E C e v l i a t c u e t c j A b O ( e c t n n e e r m e f e r e i R u q r e o r R e n d o r i O t a ) t n p e o h m S u ( c b o o D J l a n r t e t n n I e m r e o i r r e u q m e o R t s u C # n o i t d s e e t a u l e Q R A S T H : : : : l : s : r a t e r e r e r e i n b r e m d r b e o O m m t t m s e u u a e u s N N M i r t a r r u : C h e q y c d a e t i r r P t R u n t P O e a d e I r T b o t J a e H t i d u A b o J – 4 n o i t c e S n o i t s e u Q t i d u A b o J 9 . 2 s t n e t m e n i r e u m q e e r r i u g q n e i ? a d R g e g k c i n a f i p i t k c e n e r a d P A i # n o i t s e u Q 7 1 . 4 41 9 . 2 3 . 9 . 2 2 3 . 9 . 2 2 ? ) e r z s e i t n r i m p a t a i n e n i l o m p c o m f t o a t d x e h e g r i g a f o e k c ( h a t s r e p r s a v t o p r a d e p d e k e x i r c a A m p ? d e l l e b a l y l r e p o r p s t r a p e h t e r e W y l r e p o r p s r e n i a t n o c e h ? t d e l e r e l e h b a W l 9 1 . 4 0 2 . 4 8 1 . 4 s t n e m e r i u q e R g n i p p i h S CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group APPENDIX A – PROCESS TABLES PROCESS TABLE A : CARBURIZING CARBURIZING / CARBONITRIDING CARBONITRIDING / CARBON CORRECTION CORRECTION / NEUTRAL HARDENING / AUSTEMPERING MARTEMPERING / TEMPERING / PRECIPITATION HARDENING – AGING ........................................................... ........................................................................................... ................................................................43 ................................43 PROCESS TABLE B: NITRIDING (GAS) AND FERRITIC-NITORCARBURIZING FERRITIC-NITORCARBURIZING ( GAS OR SALT).................................................. SALT)..................................................................48 ................48 PROCESS TABLE C: ALUMINUM ALUMINUM HEAT TREATMENT..................................... TREATMENT..................................................................... ................................................................ ................................................................ ....................................54 ....54 PROCESS TABLE D: INDUCTION HEAT TREATING............................... TREATING............................................................... ................................................................ ................................................................ ..............................................58 ..............58 PROCESS TABLE E: ANNEALING / NORMALIZING / STRESS-RELIEVING................. STRESS-RELIEVING................................................. ................................................................ .....................................................62 .....................62 42 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering Austempering / Martempering Martempering / Tempering Tempering / Precipitation Precipitation Hardening Hardening - Aging All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, testing, greater frequencies, etc. When perfo rming the job audit, the auditor shall verify heat treater is conforming to the customer requirements. *Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent. **Does not apply to furnaces operating below 760C (1400F). ----Indicate “not applicable” Item # Related HTSA Question # 1.0 A1.1 3.1 3.7 A1.2 3.1 3.7 A1.3 3.2 A1.4 Category Process Steps PROCESS AND TEST EQUIPMENT REQUIREMENTS All furnaces, generators and quench systems shall have temperature indicating i nstruments. nstruments. Batch urnace Continuous Furnace * Furnace * Generators Yes Yes Yes Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer,etc. A program for furnace and generator burnout is required (applies to carbon bearing atmospheres). Yes Yes Yes Yes Yes Yes 3.2 Furnace weigh scales sh all be verified quarterly and calib rated annually annually at a minimum minimum Yes Yes ----- A1.5 3.2 ----- ----- ----- A1.6 3.2 ----- ----- A1.7 3.2 Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential in furnaces, shall be calibrated annually at a minimum. Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use. Verification of calibrati on of 3-gas analyzers with zero and span gas shall be performed weekly at a minimum. ----- ----- ----- A1.8 3.2 Yes Yes Yes A1.9 2.16 ----- ----- ----- A1.10 2.16 Oxygen probe controllers shall be calibrated quarterly at a minimum. All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard. Files shall be verified daily (or prior to use) with provers per SAE J864. ----- ----- ----- A1.11 3.2 Refractometers Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manufacturers requirements) at a minimum. ----- ----- ----- 43 ----- CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening – Aging All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, testing, greater frequencies, etc. When perfo rming the job audit, the auditor shall verify heat treater is conforming to the customer requirements. *Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent. **Does not apply to furnaces operating below 760C (1400F). ----Indicate “not applicable” Item # Related HTSA Question # 2.0 A2.1 A2.2 Category Process Steps Batch Furnace Continuous Furnace * Furnace * Generators PYROMETRY 3.2 .3 3.2 3.3 Thermocouples and calibration of thermocouples shall conform to AMS 2750D. Instrument Calibration per AMS 2750D shall be quarterly at a minimum. Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes – In Quali ualifi fied ed Work Zone ----- Yes Yes Yes – In Quali alifie fied Work Zone ----- Frequency reductions per AMS 2750D are not A2.3 3.2 3.3 allowed. CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Word Zone to a (1) calibrated test temperature sensor sensor (CTSS) (CTSS) or, (2) reside resident nt thermo thermocou coup ple (R-T/C). (R-T/C). (1) The CTB shall be within an operating temperature range of +/- 5C (or +/-10F) of the CTTS. This check shall be performed monthly. (2) Within the operating operating temperature temperature range de differe difference nce between between the CTS and RT/C readings readings shall be no no more more than than +/-1C (or (or +/-2F) +/-2F) as as determin determined ed at the time of the most recent temperature uniformity survey. This check shall be performed weekly. Any actions to correct a falling reading or validate a test result shall be documented. Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changing every two years as a minimum. Type R and B thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed every two years as a minimum. Protection Tubes shall be visually checked at the same frequency as thermocouples. A2.4 3.4 Temperature Uniformity Survey (TUS): refer to AMS 2750 for procedures. procedures. TUS frequency shall be annual and alter alter major rebuild. Temperature uniformity tolerance for hardening furnaces shall be +/- 14 C (or +/-25 F). Temperature uniformity tolerance for tempering furnaces shall shall be +/- 11 C (or +/-20 F). Minimum and maximum temperature ranges shall shall be tested per AMS 2750D. Exception: if the operating range of the Quailed work Zone is equal to or less than 85C (153 F) then only one temperature is required to be tested. tested. The The temperature temperature shall be within within the operating operating range of the Qualified Work Zone. Frequency reductions per AMS 2570 are not allowed. A2.5 3.5 Recorded temperature(s) for austentizing processes shall be controlled within +/- 90 (or +/-15F) of the set point as evidenced by continuous continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above). 44 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening – Aging All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, testing, greater frequencies, etc. When perfo rming the job audit, the auditor shall verify heat treater is conforming to the customer requirements. *Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent. **Does not apply to furnaces operating below 760C (1400F). ----Indicate “not applicable” A2.6 Related HTSA Question # 3.5 A2.7 3.2 Item # Category Process Steps Recorder temperature(s) for tempering and precipitation hardening processes shall be controlled within +/-6C (or +/10F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at at the lower tolerance limit (as defined above) Infrared pyrometers shall be calibrated to a black body furnace annually 45 Batch Furnace Yes Yes Continuous Generators Furnace * Furnace * Yes – In Quali ualifi fied ed ----Work Zone ----- CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group PROCESS TABLE A - Carburizing Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening – Aging All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer requirements. *Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent. **Does not apply to furnaces operating below 760C (1400F). ----Indicate “not applicable” Item # Related HTSA Question # 3.0 Category Process Steps Continuous Furnace * Furnace * Generators Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the signoff requirement Each Shift ----- Continuous Batch Furnace PROCESS MONITOR FREQUENCES A3.1 1.4 2.14 Moni Monito torr prim primar ary y temp temper erat atur ure e cont contro roll inst instru rume ment nt(s (s). ). A3.2 1.4 2.14 3.7 Monitor generator atmospheres. A3.3 1.4 2.14 3.7 Monitor primary furnace atmosphere control(s)**. Continuous recording ith sign-off every 2 hours. Alarm systems satisfy satisfy the sign-off requirement Continuous recording ith sign-off every 2 hours. Alarm systems satisfy the sign-off requirement A3.4 1.4 2.14 3.7 1.4 2.14 3.13 Verify primary atmosphere control method by back-up method**. Dialy Dialy Dialy For salt baths: check salt chemistry ( soluble oxides ) or decarburization on the parts shall be checked dialy. Dialy Dialy Dialy Each batch or continuous recording Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the signoff requirement A3.5 A3.6 1.4 1.12 Each Each batc batch h or continuous recording ith sign-off every 2 hours. Alarm systems satisfy the sign-off requirement ----- 1.4 2.14 A3.8 1.4 2.7 A3.9 1.4 2.12 ----- Quench Media Process Parameters -Temperature ith sign-off every 2 hours. Alarm systems satisfy the sign-off requirement A3.7 -Quench Level Dialy Dialy - Agitation Daily visual check is required - Daily visual check is required - Monitor each load in the absence of an alarm system. the absence of an alarm ----- ----- - Monitor every 2 hrs in Monitor time in furnace, cycle time or belt speed. Each batch Twice/ sh shif t & aft er er any change in the belt speed ----- Monitor load size or fixturing or loading rate as applicable. Each batch Twice/ sh shif t & aft er er any change in loading rate ----- Quench Delay Time – Alarm system shall be based on the time that the load exits the furnace to the time the load is at the Each batch Each bask et et f or or pusher type continuous furnac furnaces. es. Not Not applicable for belt furnaces. ----- bottom of the quench tank. 46 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening – Aging All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer requirements. *Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent. **Does not apply to furnaces operating below 760C (1400F). ----Indicate “not applicable” Item # Related HTSA Question # 4.0 A4.1 A4.2 Category Process Steps Batch Furnace Generators Continuous Furnace * Furnace * IN-PROCESS/FINAL TEST FREQUENCIES 1.4 .15 1.4 2.15 Microstructure Daily per furnace Daily per fur nace Surface hardness Each Batch Every 2hours minimum ---- ----- A4.3 1.4 2.15 Core hardness (when specified) Each Batch Every 4 hours ----- A4.4 1.4 2.15 Case depth (when specified) Each Batch Every 4 hours ----- Polymer Quench Media -Concentration Daily Da Daily - Quench Quenchabi abilit lity y Check; Check; e.g., e.g., coolin cooling g curve, curve, viscos viscosity ity,, or titrati titration on Every Every six months months Every Every six months months --------- Water Quench Media - Suspended solids Salt Quench Media Every six months Every six months ----- Ever Every y six six mont months hs Ever Every y six six mont months hs ----- Daily Daily Every six months Every six months Quarterly Quarterly ----- 2x / week 2x / week ----- Daily Daily Each shift Each shif t --------- 5.0 A5.1 A5.2 A5.3 A5.4 A5.5 QUENCHANT AND SOLUTI ON ONS TEST FREQUENCIES 2.12 3.14 2.12 3.14 2.12 3.14 2.12 3.14 3.14 2.12 3.14 3.14 A5.6 2.13 A5.7 2.11 - Analysis & Contaminants Brine or Caustic Quench Media - Concen Concentra tratio tion n and/o and/orr Speci Specific fic Gravity - Suspended solids Oil Quench Media -Water -Water conten content, t, suspen suspended ded solids solids,, viscosity, cooling curve, total acid, and flash point. Rust Preventive - Soluble Oil - Concentration Washers - Concentration of cleaner - Temperature of solution (required if temperature is specified to be above ambient temperature). 47 ---- ----- CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing Ferritic-Nitrocarburizing (Gas or Salt) All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements requirements,, e.g., inspection inspection test ing, greater frequencies, frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers customers requirements. requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as specified, specified, whichever whichever is more frequent. frequent. ----- indicate “not applicable” Item # Related HTSA Question # 1.0 B1.1 3.1 3.7 B1.2 3.1 3.7 B1.3 B1.3 Category Process Steps PROCESS AND TEST EQUIPMENT REQUIREMENTS Ali furnaces, generators and quench systems s hall have temperature indicating instruments instruments.. Batch Furnace Continuos Furnace* Gene Genera rato tors rs SaltBa SaltBath th Y es Y es Y es Yes Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc. Y es Y es Y es Yes – For temperature only 1.18 1.18 A prog progra ram m for for furn furnac ace e and and gene genera rato torr burn burnou outt is required. required. Not required required for retort gas nitriding. nitriding. Y es Y es Y es ----- B 1.4 3.12 3.13 For austentizing salt baths: baths: Salt chemistry chemistry (soluble oxides) or decarburization on the parts, shall be checked daily. ----- ----- ----- Ye s B1.5 B1.5 3.2 3.2 Furn Furnac ace e weig weigh h scal scales es shal shalll beverif beverifie ied d quar quarte terl rly y and and calibrated calibrated annually annually at a minimum. minimum. Y es Y es ----- ----- B1.6 B1.6 3.2 3.2 Dew Dew poin pointe ters rs and and gas gas analy nalyze zers rs,, used used to verify verify proper proper atmosphere i n furnaces, s hall be calibrate calibrated d annually annually at a minimum. ----- ----- ----- ----- B1.7 B1.7 2.16 2.16 All All hard hardne ness ss test test equi equipm pmen entt (for (for each each scal scale e used used)) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard. ----- ----- ----- ----- B1.8 B1.8 2.16 2.16 File Files s shal shalll be veri verifi fied ed dail daily y (or (or prio priorr to use)wi use)with th provers per SAE J864. ----- ----- ----- ----- B1.9 B1.9 3.2 3.2 Refra efract cto omete meters rs (typ typical ically ly used sed to checkpo heckpolyme lymer r quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manufacturer’s requirements) at a minimum. ----- ----- ----- ----- 48 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt) All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers customers requirements. requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as specified, specified, whichever whichever is more frequent. frequent. ----- indicate “not applicable” Item # Related HTSA Question # 2.0 Category Process Steps Batch Furnace Continuos Furnace* Gene Genera rato tors rs SaltBa SaltBath th PYROMTERY B2.1 3.2 3.3 Thermocouples and calibration of thermocouples shall conform to AMS 2750D. Y es Y es Y es Yes B2.2 3.2 3.3 lnstrument Calibration per AMS 2750D shall be Y es Y es Y es Yes Y es Ye s Y es Yes quarterly at a minimum. Frequency reductions per AMS 2750 are not allowed. B2.3 3.2 3.3 CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated temperature sensor (CTTS) or, (2) resident thermocouple thermocouple (R-T/C). (R-T/C). (1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly. (2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/-1 C (or +/- 2F) of relationship determined determined at the time of the most recent temperature uniformity survey; this checked shall be performed weekly. Any action to correct a failing reading or validate a test result shall be documented. Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked for equipment operating below 760C (1400F) and changed every two years at a minimum. Type R and S thermocouple shall be checked monthly for equipment operating at or above 760C (1400F) and changed every tow years at a minimum. Protection Tubes shall be visually checked at same frequency as thermocouples. 49 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt) All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements requirements,, e.g., inspection inspection testing, greater f requencies, requencies, etc. When performing performing the job audit, the auditor shall verify heat treater is conforming to the customers customers requirements. requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as specified, specified, whichever is more frequent. frequent. ----- indicate “not applicable” Item # Related HTSA Question # B2.4 3.4 Category Process Steps Temperature Uniformity Survey (TUS): refer to AMS 2750Dfor procedures. TUS frequency shall be annual Batch Furnace Continuos Furnace* Gene Genera rato tors rs SaltBa SaltBath th Y es Yes – In Qualified Work Zone ----- Yes Y es Yes – In Qualified Work Zone ----- Yes and after major rebuild. rebuild. Temperature uniformity uniformity tolerance shall be +/- 9C (15 F) Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range range of the Qualifies Qualifies Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone. Frequency reductions per AMS 2750D are not allowed. B2.5 B2.5 3.5 3.5 Reco Record rded ed temp temper erat atur ure( e(s) s) shal shalll be cont contro roll lled ed with within in +/+/9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above). B2.6 B2.6 3.2 3.2 Infr Infrar ared ed pyro pyrome mete ters rs shal shalll be cali calibr brat ated ed to a bla black body body Furnace annually. 50 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt) All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers customers requirements. requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as specified, specified, whichever is more frequent. frequent. ----- indicate “not applicable” Item # Related HTSA Question # 3.0 Category Process Steps Batch Furnace Continuos Furnace* Gene Genera rato tors rs SaltBa SaltBath th PROCESS MONITOR FREQUENCIES B3.1 1.4 2.14 Moni Monito torr prim primar ary y temp temper erat atur ure e cont contro roll inst instru rume ment nt(s (s). ). Each Each batc batch h or continuous recording with sign-off every 2 hours. larm systems satisfy the sign-off requirement B3.2 1.4 2.14 3.7 Monitor generator atmospheres, if applicable. B3.3 1.4 2.14 3.7 Mo ni ni to to r p ririm ar ar y f ur ur na na ce ce at mo mos ph phe re re c on ont ro ro l( l( s) s) . E ac ac h ba tc tc h (rotary furnaces only) or continuous recording with sign-off every 2 hours. larm systems satisfy the sign-off requirement Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement B3.4 1 .4 3.7 Dissoc Dissociat iation ion of ammoni ammonia a shall shall be checke checked d in gas nitrid nitriding ing.. Each Each batch batch and every 4 hours minimum Every 4 hours B3.5 1.4 3.7 Gas Gas rati ratios os for ferri ferriti tic c nitro nitroca carb rbur uriz izin ing g shal shalll be chec checke ked. d. Each Each batc batch h Ever Every y 2 hour hours s minimum B3.6 1.4 2.14 3.13 ----- ----- Check salt chemistry (soluble oxides) in salt baths Used for austenitizing, or decarburization on the parts. 51 Each lot or Each Each Shif Shiftt continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement ----- ----- Ever Every y 2 hours hours & after any change Continuous ----- Daily Daily N/A ----- Daily ----- CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt) All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers customers requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as specified, specified, whichever is more frequent. frequent. ----- indicate “not applicable” Item # B3.7 Related HTSA Question # 1.4 2.12 B3.8 1.4 2.14 B3.9 1.4 2.7 B3.10 1.4 2.12 4.0 Category Process Steps Batch Furnace Continuos Furnace* Gener enerat ator ors s SaltBa SaltBath th Quench Media Process Parameters - Temperature Each batch or continuous recording with sign-off every 2 hours. larm systems satisfy the sign-off requirement Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement ----- --------- Each batch or continuous recording with sign-off every 2 hours. larm systems satisfy the sign off requirement - Quench Level Daily Daily - Agitation - Daily -Monitor each load in the absence of an alarm system. - Daily - Monitor every 2 hours in the absence of an alarm system. Mo ni ni to to r t im im e i n f ur ur na nac e, e, c yc yc le le t im im e or b el el t s pe pe ed ed. E ac ac h ba tc tc h T wi wic e/ e/ sh shif t & after any change in the belt speed ----- Each batch Moni Monitor tor load load size size or fixtur fixturin ing g or load loadin ing g rate rate as appl applic icab able le.. Each Each batc batch h ----- Each batch Quench Delay Time ifif applicable Alarm system shall be based on the time that the load exits the furnace furnace to the time the load is at the bottom bottom of the quench tank. Each Each batc batch h Twic Twice/ e/sh shif iftt & after any change in loading rate. Each Each bask basket et if applicable ----- Each batch ----- Daily per furnace ----- Each batch Daily Daily IN- PROCESS/FINAL PROCESS/FINAL TEST FREQUENCIES FREQUENCIES B4.1 1.4 2.15 Microstructure Daily per furnace Daily per furnace furnace B4.2 1.4 2.15 Surface hardness Each batch Every 2 hours minimum B4.3 1.4 2.15 Core hardness (when specified) Each batch Every 4 hours ----- Each batch B4.4 1.4 2.15 Case depth (when specified) Each batch Every 4 hours ----- Each batch 52 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt) All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements requirements,, e.g., inspection inspection testing, greater frequencies, frequencies, etc. When performing performing the job audit, the auditor shall verify heat treater is conforming to the customers customers requirements. requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as specified, specified, whichever is more frequent. frequent. ----- indicate “not applicable” Item # Related HTSA Question # B5.2 B5.3 B5.4 B5.5 B5.6 Continuos Furnace* Gene Genera rato tors rs SaltBa SaltBath th 2.12 Polymer Quench Media 3.14 - Concentration Daily Daily ----- ----- - Quenchability Check; e.g., cooling curve, viscosity, or titration Every six months Every six months ----- ----- Every six months Every six months ----- ----- Every six months Every six months ------- Ever Every y six six months Daily Daily ----- ----- Every six months Every six months ----- ----- Qua rt rt el ely Quartely ----- ----- 2.12 Water Quench Media 3.14 - Suspended solids 2.12 Salt Quench Quench Media 3.14 - Analysis & Contaminants 2.12 Brine or Caustic Quench Media 3.14 - Concentration and/or Specific Gravity - Suspended solids 2.12 3.14 Oil Quench Media - Water content, suspended solids, viscosity, cooling curve, total acid, and flash point. 2.13 Rust Preventive Preventive - Soluble Soluble Oil - Concentration B5.7 Batch Furnace QUENCHANT AND SOLUTION TEST FREQUENCIES Quench Media Controls If Applicable 5.0 B5.1 Category Process Steps 2.11 2x / week 2x / week ----- 2x / week Daily Daily ----- Daily Each si ftft Each si ftft Washers - Concentration of cleaner - Temperature of solution (required if temperature is specified to be above ambient temperature). temperature). 53 ----- Each sift CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group PROCESS TABLE C - Aluminum Heat Treating All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements requirements,, e.g., inspection inspection testing, greater frequencies, frequencies, etc. Wh en performing the job audit, the auditor shall verify heat treater is conforming to the customers customers requirements. requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as specified, specified, whichever is more frequent. frequent. ----- indicate “not applicable” Item # Related HTSA Question # atch Solution Continuous Solution Annealing Treating and Aging Treating and Aging Furnace urnaces Furnaces Category Process Steps PROCESS PROCESS AND TEST EQUIPMENT EQUIPMENT REQUIREMENTS 1.0 C1.1 3.1 3.7 All furnaces and quench systems shall have temperature indicatinq instruments. instruments. Yes Yes Yes C1.2 3.1 3.7 Continuous strip charts and/or data loggers are required for temperature sensors. Yes Yes Yes C1.3 C1.3 2.16 2.16 All All hard hardne ness ss test test equi equipm pmen entt (for (for each ach scal scale e used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard. ----- ----- ----- C1.4 C1.4 3.2 3.2 Furn Furnac ace e weig weigh h scal scales es shal shalll be veri verifi fied ed quar quarte terl rly y and and calibrated annually at a minimum Yes Yes Yes C1.5 C1.5 3.2 3.2 Refr Refrac acto tome mete ters rs (typ (typic ical ally ly used used to chec check k poly polyme mer r quenchants and washer solutions) shall be verified ----- ----- ----- daily (with distilled water) and calibrated annually (per manufacturers’ requirements) at a minimum. 54 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE C - Aluminum Heat Treating All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers requirements. requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as specified, specified, whichever is more frequent. frequent. ----- indicate “not applicable” Item # Related HTSA Question # 2.0 atch Solution Continuous Solution Annealing Treating and Aging Treating and Aging Furnace urnaces Furnaces Category Process Steps PYROMETRY C2.1 3.2 3.3 Thermocouples and calibration of thermocouples shall conform to AMS 2750D. Yes Yes Yes C2.2 3.2 3.3 Instrument Instrument Calibration Calibration per AMS 2750D shall be quarterly at a minimum. Frequency Frequency reductions reductions per AMS 2750D are not allowed. allowed. Yes Yes Yes C2.3 3.2 3.3 CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone Yes Yes Yes to a (1) calibrated temperature sensor (CTTS) or, (2) resident thermocouple thermocouple (R-T/C). (R-T/C). (1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly. (2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/-1 C (or +/- 2F) of relationship determined at the time of the most recent temperature uniformity survey; this checked shall be performed weekly. Any action to correct a failing reading or validate a test result shall be documented. Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked for equipment operating below 760C (1400F) and changed every two years at a minimum. Type R and S thermocouple shall be checked monthly for equipment operating at or above 760C (1400F) and changed every tow years at a minimum. Protection Tubes shall be visually checked at same frequency as thermocouples. 55 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group PROCESS TABLE C - Aluminum Heat Treating All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customers customers requirements. requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as specified, specified, whichever is more frequent. frequent. ----- indicate “not applicable” Item # Related HTSA Question # C2.4 C2.4 3.4 3.4 Category Process Steps Temp Temper erat atur ure e Unif Unifor ormi mity ty Surv Survey ey (TUS (TUS): ): refe referr to AMS AMS 2750D for procedures. TUS frequency shall be quarterly and alter major rebuild. atch Solution Continuous Solution Annealing Treating and Aging Treating and Aging Furnace urnaces Furnaces Yes Yes – In Qualified W or ork Yes Zone Temperature uniformity tolerance tolerance for solution treating and aging furnaces furnaces shall shall be +/- 6 C ( or +/- 10 F). Temperature uniformity tolerance for annealing furnaces furnaces shall be +/+/- 14 C (+/- 25 F). Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range range of the Qualifies Qualifies Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone. C2.5 C2.5 3.5 3.5 C2.6 C2.6 3.5 3.5 Frequency Frequency reductions reductions per AMS 2750D are not allowed. Reco Record rded ed temp temper erat atur ure( e(s) s) shal shalll be cont contro roll lled ed withi ithin n +/+/6C (10F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance tolerance limit (as defined defined above). above). Reco Record rded ed temp temper erat atur ure( e(s) s) shal shalll be cont contro roll lled ed withi ithin n +/+/9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance tolerance limit (as defined defined above). above). C2.7 C2.7 3.2 3.2 Infr Infrar ared ed pyr pyrome ometers ters sha shall be cali calibr brat ated ed to a black body furnace annually 56 Yes Yes – In Qualified W or ork Zone ----- - ---- ----- Yes CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE C - Aluminum Heat Treating All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, requirements, e.g., inspection inspection testing, greater greater frequencies, frequencies, etc. When performing performing the job audit, the auditor shall verify heat treater is conforming to the customers customers requirements. requirements. *Continuous *Continuous furnace frequencies frequencies are per lot (work order) or as s pecified, pecified, whichever whichever is more frequent. frequent. ----- indicate “not applicable” Item # .0 C3.1 C3.2 Related HTSA Question # atch Solution Treating and Aging urnaces Category Process Steps P R O CE SS O NI TO R F R EQ UEN C IE S Monitor primary temperature control instrument(s). 1.4 2.14 ontinuous Solution Treating and Aging urnaces Each batch or continuous Each lot or continuous recording with sign-off recording with sign-off every 2 hours. Alarm every 2 hours. Alarm systems satisfy the sign-off systems satisfy the signrequirement off requirement 1.4 Quench Media Process Parameters 2.12 2.12 - Heat Heat treate treaterr shal shalll spec specify ify temper temperatu ature re range range based based on Each batch or continuous Each lot or continuous recording with sign-off recording with sign-off product form and material. material. Temperature shall be Annealing Furnace Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy satisfy the signoff requirement ----- monitored as noted. every 2 hours. Alarm every 2 hours. Alarm systems satisfy the sign-off systems satisfy the signrequirement off requirement - Quench Level Daily Daily ----- - Agitation - Daily visual check is required - Daily visual check is required ----- - Monitor each load in the - Monitor each load in the absence of an alarm absence of an alarm system. system. C3.3 1.4 2.14 Monitor process cycle time Each batch Twice/shif t & after any change in the indexing speed Each batch C3.4 1.4 2.7 1.4 2.12 Monitor load size or fixturing as applicable. Each batch Twice/shif t & after any change in loadinq rate Each batch Quench Delay Time Quench delay time shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank. I N -P -P R O CE SS /F I N AL T ES T F RE Q UE NCI ES Each batch Each batch ----- Hardness or tensile testing (post aging), Each batch Every 4 hours Each batch or every 4 hours for continuous furnaces C3.5 4.0 C4.1 1.4 2.15 5.0 C5.1 Q UE NC H AN T AN D S O L U TI O N TE S T FREQUENCIES Polymer Quench Media 2.12 3.14 3.14 C5.2 C5.3 - Conc Concen entr trat atio ion n Daily Daily ----- - Suspended solids Every six month Every six month ----- Every six month Every six month ----- 2.12 - Quenchability Check; e.g., cooling curve, viscosity, or titration Water Quench Media 3.14 3.14 - Susp Suspen ende ded d soli solids ds Every six month Every six month ----- - Concentration of cleaner Daily Daily Daily - Temperature of solution (required if temperature is specified to be above ambient temperature). Each shift Each shift Each shift 2.11 Washers 57 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 PROCESS TABLE D Automotive Industry Action Group - Induction Heat Treating All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When perfoming the job audit, the auditor auditor shall verify heat treater is conforming conforming to the customers customers requirements requirements.. ----- indicate “not applicable” Item # SP- HTSA Clause # 1.0 Per Coil Category Process Steps PROCESS AND TEST EQUIPMENT REQUIREMENTS Per customer requirement D1.1 --- D1. D1.2 2.1 2.16 All All har hardne dness test test equip quipme men nt (for for each ach scal scale e used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard. ----- D1.3 1.3 2.1 2.16 ----- D1.4 3.2 File Files s shal shalll be verif rified ied dail daily y (or (or prio rior to use) se) with provers per SAE J864 Refractometers (typicall y used to check polymer quenchants and washer solutions) shall be verified each shift (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum. 58 ----- CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE D - Induction Heat Treating All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When perfoming the job a udit, the auditor shall verify heat treater is conforming conforming to the customers customers requirement requirements. s. ----- indicate “not applicable” Item # 2 .0 D2.1 D2.1 SP- HTSA Clause # 3.2 3.2 Category Process Steps Per Coil PYROMETRY Infr Infrar ared ed pyro pyrome mete terrs shal shalll be cali calib brated ted to a black body furnace furnace annually annually ----- PROCESS MONITORING FREQUENCIES 3.0 All All proces process s parame parameter ters s shall shall be checed checed the beginn beginning ing of every every shift shift,, tool tool change change,, or any equipm equipment ent repa repair ir.. In abse absenc nce e of proc proces ess s para parame mete terr alar alarms ms,, also also chec chec Proc Proces ess s parame paramete ters rs at end end of shif shiftt or lot lot (whichever is the greater frequency). D3.1 1.4 2.12 Quench Media Process Parameters - Temperature Alarm system for high and low temperature is required. - Quench Level Daily - Quen Quench ch Pres Pressu surre and and Flow Flow - Quenc uench h pre pressur ssure e and and flow flow may may checked at manifold. Quench flow shall be checked visually at each coil. - In the absence of an alarm system, monitor every 2 hours or after any change D3.2 1.4 2.14 Monitor cycle ti time Check cycle time at start up and after any process change. D3.3 1.4 2.14 3.16 Monitor: 1) Volts or Amps, and 2) Kilowatts Use of an energy monitor or signature monitor satisfies 1) and 2). - this requirement applies to each power supply (not per coil) 59 - in the absence absence of an alarm system, monitor every 2 hours or after any change CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 PROCESS TABLE D Automotive Industry Action Group - Induction Heat Treating All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, requirements, e.g., in spection spection testing, greater frequencies, frequencies, etc. When perfoming the job audit, the auditor auditor shall verify heat treater is conforming conforming to the customers customers requirement requirements. s. ----- indicate “not applicable” Item # SP- HTSA Clause # Category Process Steps IN-PROCESS/FINAL IN-PROCESS/FINAL TEST FREQUENCIES 4.0 D4.4 1.4 2.15 Induction pattern length D4.5 1.4 2.15 T ot otal or Effective Case depth D4.6 1.4 2.15 Surface hardness D4.7 1.4 2.15 Core Core hard hardne ness ss (whe (when n spec specif ifie ied) d) D4.8 1.4 2.15 Microstructure 60 Per Coil Production Setup or Coil Change Per Coil (1st Piece lnspection) 1 part at start- up, end of production run, and every 4 hours minimum, minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc) 1 part at start- up up, end of production run, and 1 part per 8 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc) 1 part at start- up, end of production run, and every 4 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc) 1 part part at star startt-up, -up, end end of production run, and every 4 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc) 1 part at start- up, end a part pre And 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc) CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE D - Induction Heat Treating All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When perfoming perfoming the job audit, the auditor shall verify verify heat treater is conforming conforming to the customers customers requirement requirements. s. ----- indicate “not applicable” Item # SP- HTSA Clause # IN PROCESS/FINAL PROCESS/FINAL TEST FREQUENCIES Quench Media Controls If Applicable 5.0 D5.1 D5.2 D5.3 Per Coil Category Process Steps 2.12 3.14 Polymer Quench Media - Concentration - Quenchability Check; e.g., e.g., cooling curve, viscosity, or titration Water Quench Quench Media - Suspended solids Brine or Caustic Quench Media 2.12 3.14 2.12 3.14 D5.4 2.13 D5.5 2.11 Once per day Monthly Quarterly - Concentration and/or Specific Gravity Monthly - Suspended solids Quarterly Rust Preventive - Soluble Oil - Concentration ashers - Concentration of cleaner 2x / week - Temperature of solution (required if temperature is specified to be above ambient ambient em erature erature . Each shift Daily 61 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 PROCESS TABLE E Automotive Industry Action Group – Annealing / Normalizing / Stress-Relieving Stress-Relieving All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer requirements. *Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent. **Does not apply to furnaces operating below 760C (1400F). ----Indicate “not applicable” Item # Related HTSA Question # 1.0 Category Process Steps Batch Furnace Continuous Furnace * Furnace * Generators PROCESS AND TEST EQUIPMENT REQUIREMENTS E1.1 3.1 3.7 All furnaces, generators and quench systems (where applicable) shall have temperature indicating instruments. Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer,etc. Yes Yes Yes E1.2 3.1 3.7 Yes Yes Yes E1.3 1.3 3.2 Furn Furna ace weig weigh h scal scales es shal shalll be verif erifie ied d quar quarte terrly and calibrated calibrated annually annually at a minimum Yes Yes ----- E1.4 3.2 Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential in furnaces, furnaces, shall be calibrated annually at a minimum. This is applicable when used in controlling carbon-bearing atmospheres. ----- ----- ----- E1.5 E1.5 3.2 3.2 Veri Verifi fica cati tion on of cali calibr bra ation tion of spec spectr trom omet eter ers, s, and and carb carbon on IR combustion analyzers, shall be checked daily or prior to use. This is applicable when used in controlling carbon-bearing atmospheres. ----- ----- E1. E1.6 3.2 Veri Verifi fica cati tion on of cali calibr bra ation tion of 3-ga 3-gas s anal analyz yzer ers s with with zero zero and span gas shall be performed weekly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres. ----- ----- ----- E1. E1.7 3.2 Oxy Oxygen gen probe robe cont contrrolle ollerrs shal shalll be cali calib brate rated d quar quarte terrly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres. Yes Yes Yes E1. E1.8 2.1 2.16 All hard ardnes ness test equi equip pment ment (fo (for each ach sca scale use used) shal shalll be calibrated semi-annually semi-annually minimum, and verified daily minimum per the applicable applicable ASTM standard. ----- ----- ----- 62 ----- CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE E – Annealing / Normalizing / Stress-Relieving All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, testing, greater frequencies, etc. When perfo rming the job audit, the auditor shall verify heat treater is conforming to the customer requirements. *Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent. **Does not apply to furnaces operating below 760C (1400F). ----Indicate “not applicable” Item # Related HTSA Question # 2.0 Category Process Steps Batch Furnace Continuous Furnace * Furnace * Generators PYROMETRY E2.1 3.2 3.3 Thermocouples and calibration of thermocouples shall conform to AMS 2750D. Yes Yes Yes E2.2 3.2 3.3 Instrument Calibration per AMS 2750D shall be quarterly at a minimum. minimum. Yes Yes Yes E2.3 3.2 3.3 Yes Yes Yes Frequency reductions per AMS 2750D are not allowed. CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated temperature sensor (CTTS) or, (2) resident thermocouple thermocouple (R-T/C). (1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly. (2) The relationship between the CTS and R-T/C at the operating operating temperatur temperature e range range shall shall be be within within +/-1 +/-1 C (or (or +/+/2F) of relati relationshi onship p determ determined ined at the time of the the most recent recent temperature uniformity survey; this checked shall be performed weekly. Any action to correct a failing reading or validate a test result shall be documented. Additionally, Type K and N thermocouples shall be checked monthly for equipment equipment operating at or above above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked for equipment operating below 760C (1400F) and changed every two years at a minimum. Type R and and S thermocou thermocouple ple shall be checked checked monthly monthly for equipment operating at or above 760C (1400F) and changed every tow years at a minimum. Protection Tubes shall be visually checked at same frequency as thermocouples. 63 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 PROCESS TABLE E Automotive Industry Action Group – Annealing / Normalizing / Stress-Relieving Stress-Relieving All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer requirements. *Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent. **Does not apply to furnaces operating below 760C (1400F). ----Indicate “not applicable” Item # E2.4 E2.4 Related HTSA Question # 3.4 3.4 Category Process Steps Temp Temper erat atur ure e Unif Unifo ormit rmity y Survey rvey (TU (TUS): S): refer efer to AMS 2750D for procedures. TUS frequency shall be annually and alter major rebuild. Temperature uniformity tolerance for annealing furnaces furnaces shall be +/- 14 C (+/- 25 F). Temperature Temperature uniformity uniformity tolerance tolerance for tempering tempering furnaces furnaces shall be +/- 11 C ( or +/+/20 F). Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range range of the Qualifies Qualifies Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone. Frequency reductions per AMS 2750D are not allowed. E2.5 E2.5 3.5 3.5 Recor ecorde ded d temp tempe eratu rature re((s) sha shall be con control trolle led d with ithin +/+/9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance tolerance limit (as defined defined above). above). 64 atch Furnace Continuous Furnace * Furnace * Generators CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 PROCESS TABLE E – Annealing / Normalizing / Stress-Relieving Stress-Relieving All requirements given below are subordinate to customer specific requirements. The customer may have additional requirements, e.g., inspection testing, testing, greater frequencies, etc. When perfo rming the job audit, the auditor shall verify heat treater is conforming to the customer requirements. *Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent. **Does not apply to furnaces operating below 760C (1400F). ----Indicate “not applicable” Item # Related HTSA Question # 3.0 Category Process Steps Generators Continuous Furnace * Furnace * PROCESS MONITOR FREQUENCES E 3.1 1.4 2.14 Monitor primary temperature control instrument(s). E 3.2 1.4 2.14 3.7 Monitor generator atmospheres. E 3.3 1.4 2.14 3.7 Monitor primary furnace atmosphere control(s)**. E 3.4 Batch Furnace Each batch or continuous recording with sign-off sign-off every2 hours. Alarm systems satisfy the sign-off requirement Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the signoff requirement ----- Each Shift ----- Continuous recording with sign-off every 2 hours. Alarm systems Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement satisfy the sign-off requirement Continuous ----- 1.4 2.14 3.7 1.4 2.14 3.13 Verify primary atmosphere control method by back-up method**. Dialy Dialy For salt baths: check salt chemistry ( soluble oxides ) in salt baths or decarburization on the parts. Dialy Dialy E3.6 1.4 2.14 Monitor time in furnace, cycle time or belt speed. Each bat ch ch Twice/shif t & afte r a ny ny change in the belt speed ----- E3.7 1.4 2.14 Monitor load size or fixturing or loading rate as Each bat ch ch Twice/shif t & afte r a ny ny change in the belt speed ----- E 3.5 4.0 applicable. Dialy ----- IN-PROCESS/FINA IN-PROCESS/FINAL L TEST FREQUENCIES E.4.1 1.4 2.15 Microstructure (when specified) Dail Daily y per per furn furnac ace e Dail Daily y per per furn furnac ace e E.4.2 1.4 2.15 Surface hardness (when specified) Each bat ch ch Ever y 4 hours minimum E.4.3 1.4 2.15 Core hardness (when specified) Each batch Every 4 hours 2x / week 2x / week - Concentration Concentration of cleaner Daily Daily - Temperature of solution (required if temperature is Each shift Each shift 5.0 E.5.1 ---- ----- ----- SOLUTION TEST FREQUENCIES 2.13 Rust Preventive– Soluble Oil - Concentration E.5.2 2.11 ----- Washers specified to be above ambient temperature). 65 ----- CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group GLOSSARY See also SAE J415 for additional definitions of heat treating terms AIAG: Automotive Industry Action Group AMS: Aerospace Aerospace Material Specifications Specifications ASTM: American Society for Testing and Materials CTS: Control Temperature Sensor CTTS: Calibrated Test Temperature Sensor Capability: The total range of inherent variation in a stable process. Control Control Plans: Plans: Writte Written n descri descripti ption onss of the syste system m for contro controlli lling ng proce processe ssess for produ producti ction on of parts parts or bulk materials. Control Plans are written by organizations organizations to address the important characteristics characteristics and engi engine neer erin ing g requ requir irem emen ents ts of the the prod produc uct. t. Each ach part part m st hav have a Cont Contro roll Pla Plan, but but in many any case cases, s, "family" Control Plans can apply to a number of parts produced using a common process. service parts parts critical critical for the operatio operation n of equipm equipment. ent. Extended Extended delay delay Critical Spare Parts List: A list of service obtaining spare parts would result in unacceptable delays in the heat treat operation. in team of empl employ oyee eess tha that repr repres esen entt the the diff diffeeren rent func functi tion onss with within in an Cross-Functio Cross-Functional nal Team: A team orga organi niza zati tion on.. The The team team will will typi typica call lly y cons consist ist of an oper operat ator or,, line line supe superv rvis isio ion, n, proc proces esss engi engine neer er,, metallurgist, metallurgist, and quality personnel. Customer: The recipient of the organization's or supplier's product or service. Customer Customer Requirement Requirements: s: This This term term refe refers rs to the the requ requir irem emen ents ts or spec specif ific icat atio ions ns from from the the orig origin inal al equipm equipment ent manuf manufac actu turer rer (typic (typical ally ly the autom automobi obile le compa company) ny).. These These may may be ident identifi ified ed in the contra contract ct or purchase order, in engineering engineering standards, part specifications, specifications, etc. Dew Pointer: A meter especially suited for measuring the dew point of carbon-bearing atmospheres. Dew point is used to indirectly determine the carbon potential of the atmosphere. Energy Monitor: Monitor: An electr electron onic ic monit monitor or that that measu measures res and and displa displays ys the actua actuall energy energy delive delivered red to the induction heating coil. Furnace Monitoring Systems: A system that monitors the operation of the furnace. organiza izatio tion n that that perfo perform rmss heat heat treat treating ing (see (see 1.2 Appli Applica catio tion) n) to produc productio tion n and/o and/or r Heat Treater: Treater: An organ serv servic icee part parts. s. The The heat heat treat treatin ing g may may be inte intern rnal al or "cap "capti tive ve"" to a manu manufa fact ctur urin ing g orga organi niza zati tion on,, or a separate commercial commercial heat treating supplier. HTSA: Heat Treat System Assessment IR: Infrared Nonconforming Product: Product that does not conform to the customer requirements. Oxidizing Oxidizing Burn-Out: A proce process ss to remove remove any residu residual al ammo ammonia nia from the furna furnace. ce. The proce process ss usual usually ly involves removing most of the carbon-bearing protective atmosphere and then introducing oxygen. in-situ u measu measurin ring g probe probe that that deter determi mines nes the partia partiall pressu pressure re of oxyg oxygen en in carbo carbonnOxygen Oxygen Probe: An in-sit bearing atmospheres. This measurement provides an indirect measurement for the carbon potential of the atmosphere. 66 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 Process Process Tables: Tables: Table Tabless in the HTSA HTSA that that list list fue required required proces processs contro controls ls for the heat heat treat treat proce processe ssess covered. These tables contain minimum requirements. Qualified Qualified Work Zone: The defined portion of a furnace volume where temperature variation conforms to the required uniformity tolerance. Quenchability Check: A measure of the cooling dynamics of the quench media. A quenchometer is the inspection machine that displays the cooling curve of the quench media. Quench Delay: Delay: The tim time dela delay y betw betwee een n the the end end of the the heat heat tre treat cycl cyclee and and the the star startt of the the quen quench ch operat operation ion.. For furna furnace ce heat heat treati treating, ng, this this is perio period d from from the time time the parts parts exit exit the the furnace furnace qualif qualifie ied d work work zone zone to the the time time the parts parts are at the bottom bottom of the quench quench tank. tank. For induc inductio tion n harde hardenin ning g system systems, s, this this is the time from the end of the heat cycle to the start of the quench flow (or when the parts enter a quench tank). medium m used used to quenc quench h parts parts after after heat heat treat treating ing,, e.g., e.g., oil, oil, water water,, polym polymer, er, and Quenching Quenching Medium: Medium: The mediu salt. R-T/C: Resident Thermocouple used for comparative check of the control temperature sensor (CTS). Recipe: This This term term is typi typica call lly y used used when when a comp comput uter er--base based d syst system em sets sets and and cont contro rols ls the the proc proces esss parameters, parameters, e.g., temperature, temperature, cycle time, carbon potential. The “recipe” refers to the settings of the process parameters. Reprocessing: Any proce process ss that that is perfor performe med d on nonco nonconfo nform rming ing produ product ct so that that it will will meet meet the speci specifie fied d requirements. Responsibility Matrix: A responsibility matrix defines the designated personnel for all key functions. This matrix includes the primary and secondary designees. SAE International: Society of Automotive Engineers International Shop Traveler: Traveler: A docum document ent usuall usually y create created d in the receivi receiving ng depart departme ment nt for each each batch batch or lot of parts parts received. The document defines the process routing of the parts. Signature Signature Monitor: Monitor: An electron electronic ic monitor monitor used to monitor monitor inductio induction n heat heat treating treating systems. systems. The monitor monitor plots the energy unit, e.g., voltage or kilowatt, vs. time or distance. Special Special Characteris Characteristics: tics: are produc productt chara characte cteris ristic ticss or manuf manufac actur turing ing proce process ss param paramete eters rs which which can can affect affect safet safety y or comp complia liance nce with with regula regulatio tions, ns, fit, fit, funct function ion,, perfo perform rmanc ancee or subse subseque quent nt proce processi ssing ng of product. Refer t o customer-specific requirements. requirements. The measu easure rem ment ent of the the unif unifor orm mity ity of tem tempera peratu ture re with within in the the Temper Temperatu ature re Uniform niformity ity Survey: Survey: The qualified work zone of a furnace. Description of the method to be used is AMS 2750D. Temper Delay: Delay: The time delay from when the parts exit the quench tank to the time when the parts are placed in the tempering furna fu rnace. ce. instrument nt that measures measures carbon monoxide monoxide,, carbon carbon dioxide. dioxide. and methane methane in 3 (Th (Three ree)) Gas Gas Analyz Analyzer: er: An instrume carbon-beari carbon-bearing ng atmosphe atmospheres. res. This measurem measurement ent provides provides an indirect indirect measure measuremen mentt of the carbon carbon potentia potentiall of the atmosphere. 67 CQI-9 Special Special Process: Process: Heat Treat System Assessment Assessment Version 2, Issued 8/07 Automotive Industry Action Group Three-Val ThreeValve ve Fail-Safe Fail-Safe Vent (for ammonia ammonia fines): fines): An arrangem arrangement ent of three three valves valves that that preven prevents ts ammonia ammonia from from inadv inadvert erten ently tly ente enterin ring g the furna furnace ce during during carbu carburiz rizing ing or neutr neutral al harde hardenin ning g operat operation ions. s. The valv valves es are arranged in such a way that, when the ammonia fine to the furnace is shut off, any ammonia that might leak leak past past the valv valvee is vente vented d to the atmosp atmosphe here re and and thus thus preve prevent nted ed from from enter entering ing the furnace furnace.. See See the diagrams below. Figure 1 — Valves 1 and 2 are opened to allow ammonia flow into the furnace. Figure 2 — Valves 1 and 2 are closed to prev preven entt ammo ammoni nia a flow flow to furn furnac ace. e. If Valve 2 inadvertently leaks, ammonia is vented (Valve 3) to the atmosphere. Trap Points – Areas in containers (baskets, fixtures, shipping boxes, etc.) or equipment that may inadvertently trap parts, allowing the potential for parts to be mixed between batches. Work Instruction Instructionss – Instruc Instruction tionss that that describ describee work work conduc conducted ted in one function function in a company company,, e.g., e.g., setup, setup, insp inspec ecti tion on,, heat heat trea treatt oper operat atio ion, n, proc proces esss para parame mete terr tole tolera ranc nces es,, etc. etc. The The term term "wor "work k inst instru ruct ctio ions ns"" is synonymous with the term "job instructions." 68 CQI-9 Special Process: Heat Treat System Assessment Automotive Industry Acti on Group Version 2, Iss ued 8/07 MAINTE MAINTENAN NANCE CE REQUES REQUEST T Name of Submitter: Date: Company: Company Address: Address: Phone: Fax: E -mail: MAINTENANCE REQUEST Page Number of Change: Document Currently Reads: Recommended Changes/Should Read: Recommended Additions: Reason for Change: Signature of Submitter: DISPOSITION (AIAG USE ONLY) Manager’s Recommendation: Recommendation: Final Disposition: Disposition: Comments: Note: complete form and return to the AIAG Publication Specialist for Consideration. Send completed from to the Publication Specialist Specialist at: Automotive Industry Action Group • 26200 • 26200 Lahser Road • Suite 200 • Southfield, MI 48034 Telephone: (248) 358-3570 • Fax: (248) 358-3253 www.aiag.org 69

Aiag Cqi-9 Special Processes

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