CQI-11 电镀系统评估_v2.xls

CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Facility Name:工厂名称： Phone Number:电话： Fax Number:传真：Process Table A流程表流程表A Zinc锌 Zinc Alloy Plating锌合金电镀 Captive Plater (Y/N):职工电镀工厂 （是/否） Process Table B流程表流程表B Commercial Plater (Y/N):商业电镀 工厂（是/否） Surface Conditioning of Metals for Decorative Plating 装饰电镀的金属件调节 Date of Assessment:评估日期：Process Table C流程表流程表C Surface Conditioning of ABS Email: Personnel Contacted:人员联系方式：人员联系方式： Number of “Not Satisfactory“ Findings:“不理想”项目数：不理想”项目数： Auditors/Assessors:评审员评审员/评估员：评估员： CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Question Number 问题编号问题编号 Question问题问题Requirements and Guidance要求与标准要求与标准Objective Evidence客观证据客观证据 N/A 无无 Satisfactory理理 想想 Not Satisfactory 不理想不理想 Needs Immediate Action需要立即改需要立即改 进进 1.1 Is there a dedicated and qualified plating person on- site?现场是否有专门的，具有 相关资格的电镀人员？ To ensure readily available expertise, there shall be a dedicated and qualified plating person on the site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the postition including chemical and plating knowledge. The qualifications shall include a minimum of 5 years experience in plating and surface finishing or a combination of formal chemistry/chemical engineering education and plating experience totaling a minimum of 5 years.为了确 保能够随时得到专业指导，必须有专门的，具有相关资格的电镀人员在 场。此人必须是全职员工，其职务必须在企业组织结构中有所反应，职 责描述中必须包括确认该职位所需资历，包括化学和电镀知识。职业资 格应该包括具有电镀和表面处理五年以上工作经验，或化学/化工工程专 业教育与电镀工作相加，五年以上工作经验 N/A 1.2 Does the plater perform advanced quality planning?电 镀厂是否进行先期质量策划？ The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The plater shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.企业必须形成一项 正式的先期质量计划程序。必须进行可行性的研究，并且在每个零部件 上达成一致意见。相同的部件可以组成一个系列，由企业来界定。在零 部件批准过程被客户认可后，除非经客户批准，不然则不得擅自改动流 程。电镀厂必须与客户联系，对流程的改变进行说明，流程改变的说明 必须记录在案 N/A Special Process: Plating Process Assessment (General Facility Overview) 特殊过程：电镀流程评估（一般设施概况）特殊过程：电镀流程评估（一般设施概况） Section 1 - Management Responsibility and Quality Planning Assessment评价评价 CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Question Number 问题编号问题编号 Question问题问题Requirements and Guidance要求与标准要求与标准Objective Evidence客观证据客观证据 N/A 无无 Satisfactory理理 想想 Not Satisfactory 不理想不理想 Needs Immediate Action需要立即改需要立即改 进进 Special Process: Plating Process Assessment (General Facility Overview) 特殊过程：电镀流程评估（一般设施概况）特殊过程：电镀流程评估（一般设施概况） Assessment评价评价 1.3 Are plater FMEAs up to date and reflecting current processing?电镀厂是否更新 FMEA失效模式与后果分析， 使其能反映现有流程？ The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEAs are updated to reflect current part quality status. The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key plating process parameters as defined by the organization. A cross- functional team shall be used in the development of the FMEA. All characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA. 企业必须使用正规 的失效模式和后果分析（FMEA）程序，并确保FMEAs能够反映最新的 零件质量情况。必须对每个零部件或系列都编写FMEA，如果有具体的流 程，则每一步都要编写。任何情况下，都必须处理从零部件接收到装运 的每一步和企业所界定的所有关键电镀参数，必须组成一个综合职能团 队来开发FMEA。所有企业定义或者客户规定的特性必须在FMEA中进行 确认，定义和处理 N/A CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Question Number 问题编号问题编号 Question问题问题Requirements and Guidance要求与标准要求与标准Objective Evidence客观证据客观证据 N/A 无无 Satisfactory理理 想想 Not Satisfactory 不理想不理想 Needs Immediate Action需要立即改需要立即改 进进 Special Process: Plating Process Assessment (General Facility Overview) 特殊过程：电镀流程评估（一般设施概况）特殊过程：电镀流程评估（一般设施概况） Assessment评价评价 1.4 Are finish process control plans up to date and reflecting current processing?完成流程 控制计划是否为最新，并能反 映现有流程 企业必须使用正规的控制计划程序，确保其被更新，能够反映现行的控制。必须 为每个零部件或系列制定控制计划，如果有具体流程，则对每一步具体流程都制 定控制计划。在任何情况下，企业必须处理所有流程步骤。从零部件接受到装 运，确认企业自己对所有使用的设备和所有关键电镀流程参数进行定义，必须组 成一个综合职能团队，包括一名生产操作员，来开发控制计划，该控制计划必须 符合所有相关文件，比如工作说明，车间导示和FMEA，所有由企业客户定义的 特性，必须在控制计划中进行确定、定义和处理。评估过程和产品特性的取样数 量及频率也必须至少按流程来处理 The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls. The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key plating process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEAs. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and Frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables. N/A CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Question Number 问题编号问题编号 Question问题问题Requirements and Guidance要求与标准要求与标准Objective Evidence客观证据客观证据 N/A 无无 Satisfactory理理 想想 Not Satisfactory 不理想不理想 Needs Immediate Action需要立即改需要立即改 进进 Special Process: Plating Process Assessment (General Facility Overview) 特殊过程：电镀流程评估（一般设施概况）特殊过程：电镀流程评估（一般设施概况） Assessment评价评价 1.5 Are all plating related and referenced specifications current and available? For example: SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. 是否所有与 电镀相关的参数都是最新的， 并且可以获得？比如 SAE,AIAG,ASTM,通用,福特和 克莱斯勒 为了保证所有客户要求都能被完全理解并得到满足，企业必须将所有相 关的电镀和客户参考标准与具体要求联系起来使用，并确保这些信息是 最新的。这些标准和要求中包括由SAE,AIAG,ASTM,通用,福特,克莱斯勒 发行的文件，但并不局限于以上这些机构，企业必须制定流程，定期评 审，分发和执行所有客户/行业标准和规范，以及基于客户要求的变更， 该流程必须立即执行，不得超过2周，企业必须记录检查和执行过程并且 必须落实如何获取客户和行业文件，如何在企业中保持，如何建立现 状，以及如何将这些信息在2周内传达到车间等问题，企业还必须确定有 谁来负责这些工作。To ensure all customer requirements are both understood and satisfied, the organization shall have all related plating and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards and specifications and changes based on customer-required schedule. This process shall be executed as soon as possible and shall not exceed two weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks. N/A CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Question Number 问题编号问题编号 Question问题问题Requirements and Guidance要求与标准要求与标准Objective Evidence客观证据客观证据 N/A 无无 Satisfactory理理 想想 Not Satisfactory 不理想不理想 Needs Immediate Action需要立即改需要立即改 进进 Special Process: Plating Process Assessment (General Facility Overview) 特殊过程：电镀流程评估（一般设施概况）特殊过程：电镀流程评估（一般设施概况） Assessment评价评价 1.6 Is there a written process specification for all active processes? 所有现行的工序是 否都有书面工序规范？ The plater shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, rectifier settings, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control. All active processes should have a written process specification. These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.电镀厂必须有针对所有现行工序具体的书面规范，并明确所 有工序的步骤包括相关操作参数入温度，周期，负荷率，整流器设置， 等。这些参数必须不仅只是被定义，而且必须由企业规定允许操作玩 味，一保持对该工作的控制，所有的现行工序必须由书面的供需规范， 这些规范应该来自于操作指导，工作说明，电脑程序或其他相似的文件 。 N/A 1.7 Has a valid product capability study been performed initially and after process change?是 否在工序变更之前和之后，进 行有效的产品性能分析？ 为了证明每个工序都能生产出符合要求的产品，企业必须对每个工序进 行初始产品性能分析，在设备调整之后，或主要设施重建之后检查每一 个流程，企业必须对主要重建的构成做出定义，每一条生产线的所有工 序都必须能按照工序要求和客户的要求进行初始产品性能分析。性能分 析技术必须是用于电镀产品的属性，如：电镀厚度，防腐度，等。产品 性能必须符合客户的特定要求，如果没有客户要求，企业必须建立可行 的性能检测范围。在性能指标超出客户要求或建立的范围时必须制定改 进措施并跟进处理。To demonstrate each process is capable of yielding acceptable product the organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, and after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all plating processes per line as defined in scope of work and in accordance with customer requirements. Capability study techniques shall be appropriate for the plating product characteristics, e.g. plate thickness, corrosion resistance, etc Any specific customer requirements shall be met. In the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to be followed in case capability indices fall outside customer requirements or established ranges. N/A CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Question Number 问题编号问题编号 Question问题问题Requirements and Guidance要求与标准要求与标准Objective Evidence客观证据客观证据 N/A 无无 Satisfactory理理 想想 Not Satisfactory 不理想不理想 Needs Immediate Action需要立即改需要立即改 进进 Special Process: Plating Process Assessment (General Facility Overview) 特殊过程：电镀流程评估（一般设施概况）特殊过程：电镀流程评估（一般设施概况） Assessment评价评价 1.8 Does the plater collect and analyze data over time, and react to this data? 电镀厂是 否长期保持对数据的收集和分 析，并且根据数据进行调整 The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time. Methods of analysis shall include ongoing trend or historical data analysis of special product or process parameters. The organization shall determine which parameters to include in such analysis.对产品和 工序进行持续分析，为故障预防提供重要信息，企业必须由相应的系 统，持续不断的采集、分析、并对产品和流程数据做出反应，分析方法 必须包括对特殊产品或流程参数运行趋势或历史数据的分析，企业必须 决定对应那些参数进行这类分析。 N/A 1.9 Does management review and verify bake oven logs for parts requiring hydrogen embrittlement relief every 24 hours?管理部门是否需要每24 小时进行氢脆环节的零部件的 锅炉使用记录进行检查 Management shall review the oven monitoring systems/logs at intervals not to exceed 24 hours or prior to parts being released for shipment. The plater shall have reaction plans for non-conformances to process requirements. This is to contain, at minimum, requirements for quarantining material and notifying customer.管理部门必须不时的检查 锅炉监控记录，而不要超过24小时或在零部件发运之前，对于不符合工 序要求的部件，电镀产必须有相应的反应计划，至少包括隔离材料，并 通知客户。 N/A 1.10 Are internal assessments being completed on an annual basis, at a minimum, incorporating AIAG PSA?内部 评估是否根据AIAG的PSA每年 进行一次？ The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG PSA. Concerns shall be addressed in a timely manner.企业必须根据AIAG的PSA每年进行一次内 部评估，对发现的问题应及时进行处理 N/A CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Question Number 问题编号问题编号 Question问题问题Requirements and Guidance要求与标准要求与标准Objective Evidence客观证据客观证据 N/A 无无 Satisfactory理理 想想 Not Satisfactory 不理想不理想 Needs Immediate Action需要立即改需要立即改 进进 Special Process: Plating Process Assessment (General Facility Overview) 特殊过程：电镀流程评估（一般设施概况）特殊过程：电镀流程评估（一般设施概况） Assessment评价评价 1.11 Is there a system in place to authorize reprocessing and is it documented?是否有合适的 系统批准再进行加工，并对其 进行记录？ The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual. The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible. All reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary plating modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.质量管理系统必须包括一 个正规的再加工流程，该流程必须经指定人员认可，再加工流程必须对 再加工流程允许的或不允许的产品属性进行描述，所有再加工处理必须 要求一份新的流程控制表，该表是由具有资质的技术人员选择的必须要 电镀修正，再加工记录必须标明材料在何时，使用何种方式进行再加工 。质量经理或指定的人员必须批准对再加工产品的发放。 N/A 1.12 Does the Quality Department review, address, and document customer and internal concerns? 质量部门是 否检查，处理和记录客户意见 和内部意见？ The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem- solving approach shall be used.质量管理系统必须包括一个正规化流 程，检查流程和处理客户机其他内部意见的流程，必须使用几率严明的 解决问题方法 N/A 1.13 Is there a continual improvement plan applicable to each process defined in the scope of the assessment?每 个评估范围内的确定流程是否 有特殊可行的改进计划 The plater shall define a process for continual improvement for each plating process identified in the scope of the PSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.电镀工必须确定一个对每个在PSA范 围内的电镀流程进行持续改善的流程，该流程必须能够在质量和产量上 起到完善的作用，必须明确各项措施的先后次序，必须包括时间限制， （估计完成的日期）企业必须证明其计划的有效性。 N/A 1.14 Does the Quality Manager or designee authorize the disposition of material from quarantine status? 质量经理 或专员是否批准对隔离状态材 料的处理。 The Quality Manager or designee is responsible for authorizing and documenting appropriate personnel to disposition quarantine material. 质量经理或指定人员负责授权和使用证明由某个合适的人员来处理被隔 离的材料。 N/A CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Question Number 问题编号问题编号 Question问题问题Requirements and Guidance要求与标准要求与标准Objective Evidence客观证据客观证据 N/A 无无 Satisfactory理理 想想 Not Satisfactory 不理想不理想 Needs Immediate Action需要立即改需要立即改 进进 Special Process: Plating Process Assessment (General Facility Overview) 特殊过程：电镀流程评估（一般设施概况）特殊过程：电镀流程评估（一般设施概况） Assessment评价评价 1.15 Are there procedures or work instructions available to plating presonnel that define the plating process?电镀工是 否可以获得详细说明电镀流程 的操作指南？ There shall be procedures and work instructions available to plating personnel covering the plating process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.电镀人员必须得到包含电镀流程的工 作程序和具体说明，这些流程或说明必须包括对潜在紧急情况，（比如 停电）的处理方法，设备启动，设备关闭和产品隔离（见2.7），产品检 查和一般操作流程，这些流程或说明必须易于车间人员理解。 N/A 1.16 Is management providing employee training for plating? 管理人员是否提供有关电镀方 面的员工培训？ The organization shall provide employee training for all plating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.企业必须为员工提供所有电镀作业的培训，所有的员 工，包括后备和零时工，都必须接受培训，必须保留员工培训的相关证 明，这些证明必须包括一份培训效果评估，管理部门必须对每个岗位的 资质要求进行界定，同时落实在正在运行的或将要进行的培训。 N/A CQI-11 Special Process: Plating System Assessment Version 1 Issued 8/07 Question Number 问题编号问题编号 Question问题问题Requirements and Guidance要求与标准要求与标准Objective Evidence客观证据客观证据 N/A 无无 Satisfactory理理 想想 Not Satisfactory 不理想不理想 Needs Immediate Action需要立即改需要立即改 进进 Special Process: Plating Process Assessment (General Facility Overview) 特殊过程：电镀流程评估（一般设施概况）特殊过程：电镀流程评估（一般设施概况） Assessment评价评价 1.17 Is there a responsibility matrix to ensure that all key management and supervisory functions are performed by qualified personnel?是否编制 了责任矩阵确保所有关键管理 职能和监督职能由具有相关资 质的人员行使 The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.企业必须有责任矩阵，来确定所有关键管理和监管职能，并且 制定由谁来行使这些职能。必须明确首要的和后备的人员行使关键职能 （由企业界定），该矩阵必须随时供管理部门使用。 N/A 1.18 Is there a preventive maintenance program? Is maintenance data being utilized to form a predictive maintenance program? 是否有预防维护计划？维护数 据是否被用来形成定期的维护 计划？ The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall al