CQI-12 Coating-cn.doc

CQI-12Special Process: Coating System Assessment 特殊流程：喷涂系统评估CQI-12特殊流程：喷涂系统评估第 1 版，2007年8月出版ABOUT AIAG关于AIAGPurpose Statement 目的声明Founded in 1982, AIAG is a globally recognized organization where OEMs and suppliers unite to address and resolve issues affecting the worldwide automotive supply chain. AIAGs goals are to reduce cost andcomplexity through collaboration; improve product quality, health, safety and the environment; and optimize speed to market throughout the supply chain.美国汽车工业行动集团（AIAG）成立于1982年，是由OEM厂商和供应商联手组建的一家全球公认的著名机构，旨在体现并解决影响全球汽车供应链的诸多问题。AIAG的目标是通过相互协作，降低产品的成本及复杂性；提高产品质量，改善员工健康、安全与环境；并优化产品在整个供应链范围内的上市速度。AIAG Organization AIAG 组织构成AIAG is made up of a board of directors, an executive director, executives on loan from member companies, associate directors, a full-time staff, and volunteers serving on project teams. Directors,department managers, and program managers plan, direct and coordinate the associations activities under the direction of the executive director.AIAG 由董事会、一名执行董事、多名来自成员公司的贷款事务高级管理人员、多名副董事、一位全职职员以及为项目团队服务的志愿者组成。董事、部门经理与项目经理在执行董事的领导下，负责计划、指导和协调组织活动。AIAG Projects AIAG 项目Volunteer committees focus on business processes or supporting technologies and methodologies. They conduct research and develop, publish, and provide training on standards, conventions, standardbusiness practices, white papers, and guidelines in the areas of automatic identification, CAD/CAM,EDI/electronic commerce, continuous quality improvement, health focus, materials and project management, occupational health & safety, returnable containers and packaging systems, transportation/customs and truck & heavy equipment.志愿者委员会重点关注业务流程或是支持技术与方法。他们会开展研究，撰写并出版相关标准、协定、标准业务做法、白皮书以及指导原则，并就此提供培训；涉及的领域包括自动识别、CAD/CAM、EDI/电子商务、持续质量改进、关注健康、材料和项目管理、职业保健与安全、可回收容器与包装系统、运输/通关以及卡车与重型设备。AIAG PUBLICATIONS AIAG出版物An AIAG publication reflects a consensus of those substantially concerned with its scope and provisions. An AIAG publication is intended as a guide to aid the manufacturer, the consumer and the general public. The existence of an AIAG publication does not in any respect preclude anyone from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the publication. AIAG出版物反映出了在重大关注事项的范围及其规定上的一致意见。AIAG出版物旨在作为一个指南，以协助制造商、消费者和普通大众。AIAG出版物的存在于任何方面都不能避免有人会使用不符合本出版物的产品、流程或程序，来制造、营销、采购或使用产品。CAUTIONARY NOTICE 告诫性通知AIAG publications are subject to periodic review and users are cautioned to obtain the latest editions. AIAG出版物会进行定期审核，并告诫用户注意获取最新版本。MAINTENANCE PROCEDURE 维护程序Recognizing that this AIAG publication may not cover all circumstances, AIAG has established a maintenance procedure. Please refer to the Maintenance Request Form at the back of this document to submit a request.考虑到本AIAG出版物可能无法涵盖所有情况，AIAG已为此建立了一个维护程序。请参阅本文件后面的“维护申请表”，以提交申请。出版单位：Published by: Automotive Industry Action Group 美国汽车工业行动集团26200 Lahser Road, Suite 200Southfield, Michigan 48033Phone:电话： (248) 358-3570 Fax:传真： (248) 358-3253APPROVAL STATUS 批准状态The AIAG Quality Steering Committee and designated stakeholders approved this document for publication onAugust 1, 2007. AIAG质量指导委员会和指定的风险承担人于2007年8月1日批准本文件出版发行。AIAG COPYRIGHT AND TRADEMARK NOTICE: AIAG版权与商标的注意事项：The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. Copyright is not claimed as to any part of an original work prepared by a U.S. or state government officer or employee as part of the persons official duties. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.除非另有说明，否则所有出版材料内容的版权均归美国汽车工业行动集团所有。对由美国或州政府官员或是雇员作为其个人公务职责的一部分而编写的任何原作部分，不会提出版权诉求。AIAG保留所有权利，不得对内容进行更改，或是传播、出版或转载其中的部分内容。不得将信息部分或全部转卖给组织内的任何人或另一家公司。侵犯版权是违反联邦法律的，会受到刑事与民事处罚。AIAG和Automotive Industry Action Group是美国汽车工业行动集团的注册服务商标。 2007 Automotive Industry Action Group2007年美国汽车工业行动集团版权所有15FOREWORD 前言Automotive Industry Action Group (AIAG) committees are made up of volunteers from member companies in the automotive industry. The work of preparing process audits is done by AIAG technical committees. 汽车工业行动组（AIAG）委员会由来自汽车行业内各成员公司的志愿者组成。流程审核的准备工作是由AIAG技术委员会完成的。The main task of technical committees is to prepare Automotive Standards and System Requirements. Draft documents adopted by the technical committees are circulated to the Steering Committee for review and consensus approval. Publication of the documents requires approval by the Quality Steering Committee. 技术委员会的主要任务是准备汽车标准与系统要求。技术委员会所采用的草案文件要送交指导委员会以供审核并获得一致批准。文件的出版发行需要得到质量指导委员会的批准。The Quality Steering Committee would like to acknowledge and thank the following individuals and their companies who have contributed time and effort to the development of this document.质量指导委员会想藉此机会，表彰以下为文件的制订付出了大量时间及精力的个人及所属公司，并向他们表示感谢。ACKNOWLEDGEMENTS致谢Core Members: 核心成员：Steven Kwong General Motors CorporationGregory Lobo Ford Motor CompanyBrian Lowry Curtis Metal Finishing Company Michael Pawlyshyn General Motors Corporation Murli Prasad General Motors CorporationGordie Schafer PPG IndustriesLarry Xu Ford Motor Company.Supporting Members: 支持成员：Jim Aide The Acadian Group Jamie Brooks The Magni Group Ron Doran Henkel Corporation Albert Gelles Drken USATim Kittler PPG IndustriesJason Tylenda Henkel CorporationTABLE OF CONTENTS 目录ABOUT AIAG 关于AIAG. 1FORWORD 前言. 3ACKNOWLEDGEMENTS 致谢. 4INTRODUCTION 简介. 61 SCOPE 范围. 81.1 GENERAL总则. 81.2 APPLICATION 应用. 82 THE COATING SYSTEM ASSESSMENT PROCEDURE喷涂系统评估程序. 93 SPECIAL PROCESS: PLATING ASSESSMENT 特殊流程：喷涂评估. 10INSTRUCTIONS FOR COMPLETING THE COVER SHEET 完成封面表格的说明. 11SPECIAL PROCESS: COATING SYSTEM ASSESSMENT COVER SHEET特殊流程：喷涂系统评估封面表格 . 13INSTRUCTIONS FOR COMPLETING SECTIONS 1-2 完成第1和第2部分的说明. 14SPECIAL PROCESS: COATING PROCESS ASSESSMENT FORMS 特殊流程：喷涂流程评估表. 15JOB AUDIT 工作审核. 25INSTRUCTIONS FOR COMPLETING THE JOB AUDIT完成工作审核的说明. 25JOB AUDIT FORMS 工作审核表. 26APPENDIX A PROCESS TABLES附录A 流程表. 33GLOSSARY术语. 57MAINTENANCE REQUEST 维护申请表. 60INTRODUCTION简介General 总则The work of preparing CQI-12 Special Process: Coating System Assessment (CSA) was carried out through the AIAG Coating Work Group. These coating requirements are complementary to customer and product standards. CQI-12特殊流程的准备工作：喷涂系统评估（CSA）由AIAG喷涂工作组执行。这些喷涂要求对客户和产品标准来说是个补充。The CSA can be used to assess an organizations ability to meet the requirements in this assessment, as well as customer, regulatory, and the organizations own requirements. The CSA can also be used between an organization and its suppliers. CSA可用于评定一个组织达到本评估内要求，以及客户要求、法规要求和组织自有要求的能力。同时，CSA还可在一个组织及其供应商之间使用。In the CSA, the word “shall” indicates a requirement for purposes of the self assessment. Failure to meet the requirements results in an assessment that is either “Not Satisfactory” or “Needs Immediate Action”. The word “should” indicates a recommendation. Where the term “such as” is used, any suggestions given are for guidance only.在CSA中，“Shall”表示了出于自我评估目的的一种要求。未能达到这些要求将会导致评估不是“不令人满意”，就是“需要立即采取措施”。“should”表示是一种推荐方案。使用了术语“such as”时，则表示给出的任何建议仅作指导之用。Process Approach 流程方法The CSA supports the automotive process approach as described in ISO/TS 16949:2002. CSA支持ISO/TS 16949:2002中所描述的汽车业流程方法。Coating System Assessment Goals 喷涂系统评估目标The goal of the CSA is the development of a coating management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain. CSA的目标是开发一个可提供持续改进的喷涂管理系统，重点强调供应链中的缺陷预防以及减少差异和浪费。The CSA, coupled with an internationally recognized quality management system and applicable customer-specific requirements, defines the fundamental requirements for coating management systems. CSA，和国际公认的质量管理体系与适用的客户特定要求相结合，定义了喷涂管理系统的基本要求。The CSA is intended to provide a common approach to a coating management system for automotive production and service part organizations. CSA旨在给汽车业生产和维修件组织的喷涂管理系统提供一种普遍方法。Assessment Process 评估过程Ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to reexamine the continuing compliance with the CSA. Each assessment shall include a review of the organizations systems using the CSA. Successive Job Audits (Section 3.0 of this document) shall sample parts from different automotive component manufacturers that require compliance to the CSA document. 除非客户另行规定，否则每年都应进行一次此类评估，以重新检查其是否仍然符合CSA。每次评估都应包括使用CSA对组织系统进行的一次审核。后续的工作审核（本文件的3.0部分）应抽样检查来自要求符合CSA文件的不同汽车零配件制造商的零件。The assessment shall use the process approach to auditing as identified by the requirements ofISO/TS 16949:2002.评估应按ISO/TS 16949:2002中要求的规定，使用流程方法来进行审核。Assessor Qualifications 评估人资格Assessor(s) shall have the following specific experience to conduct the COATING SYSTEM ASSESSMENT: 评估人应具备以下特定经验以执行喷涂系统评估：1. Be an experienced quality management system (QMS) internal auditor (for example, ISO/TS 16949:2002, ISO 9001:2000) 是有丰富经验的质量管理体系（QMS）内部审计师（例如，ISO/TS 16949:2002, ISO 9001:2000）2. Assessor shall possess coating knowledge. Evidence shall include a minimum of 5 years experience in coating or a combination of formal chemical education and coating experience totaling a minimum of 5 years.评估人应具备喷涂方面的知识。证据应包括在喷涂方面最少5年的经验，或是在正规化工教育和喷涂方面合计最少5年的经验。3. Assessor shall possess knowledge of and be familiar with the application of automotive quality core tools including statistical process control, measurement systems analysis, part approval, failure mode and effects analysis, and advanced quality planning. 评估人应具备并熟悉汽车业质量核心工具应用方面的知识，其中包括统计过程控制、测量系统分析、零件批准、失效模式及后果分析以及前期质量规划。Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in item #1. 注意：如果需要一名以上评估人符合上述资质，则带头的评估人应是满足第1项中要求的人。Other Requirements 其它要求The organization shall keep records as evidence of compliance to the requirements identified in the CSA, as well as all appropriate action plans to address any unsatisfactory ratings. These records shall be readily available for review by any customer requiring compliance to the requirements within this document. 组织应保留相关记录，证明其符合CSA中所规定的要求，以及所有相应的行动计划以解决任何不令人满意的评级。这些记录应随时准备就绪，以供任何要求该组织符合本文件内要求的客户审核。1 SCOPE 范围1.1 General 总则This document specifies process requirements for an organization or its suppliers performing applicable coating, which need to: 本文件规定了对一个组织或其供应商完成适当喷涂的流程要求，其中需要：demonstrate ability to consistently provide product that meets customer and applicable regulatory requirements, and 展示能始终提供符合客户要求和适用法规要求的产品的能力，以及enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system. 通过有效应用该系统，提高客户的满意度，其中包括持续改进系统的流程。The Coating System Assessment is applicable to sites where customer-specified parts for production and/or service are processed throughout the automotive supply chain. 喷涂系统评估适用于在整个汽车业供应链中对生产和/或维修用客户特定零件进行处理的场所。1.2 Application 应用All requirements of the CSA are generic and are intended to be applicable to all organizations performing the coating operations addressed in this document, regardless of type, size, and product. CSA的所有要求均为一般性要求，旨在应用于执行本文件中所注明喷涂作业的所有组织，而不考虑类型、尺寸和产品差异。Ten Process Tables have been developed and the appropriate table(s) is to be referenced during the assessment. The Process Tables are specific to coating processes as noted below: 现已制订出10张流程表，在评估过程中可参考相应的表格。这些流程表是专门用于如下所示的喷涂流程的：Process Table A Pretreatment Aqueous Cleaning 流程表 A预处理水洗清洁Process Table B Pretreatment Mechanical Cleaning 流程表 B预处理机械清洁Process Table C Pretreatment Phosphating 流程表 C预处理磷化Process Table D Powder Coating 流程表 D粉末喷涂Process Table E Electrocoating 流程表 E电泳喷涂Process Table F Liquid (Spray) 流程表 F液体（喷雾）Process Table G Dip/Spin Coating 流程表 G渗涂/旋涂Process Table H Autophoretic Coating 流程表 H自泳漆喷涂Process Table I Convective Cure 流程表 I对流固化Process Table J Equipment 流程表 J设备These Process Tables contain requirements for: 这些流程表包含了对以下方面的要求：1. Process and Test Equipment 流程和测试设备2. Process Monitor Frequencies 流程监控频率3. In-Process/Final Test Frequencies 流程中/最终测试频率 4. Test Frequencies 测试频率The Process Tables specify the process parameters and the frequencies for checking process control parameters and parts, as well as periodic maintenance requirements. The Requirements and Guidance in the CSA form will notify the assessor when to refer to the Process Tables. 流程表规定了流程参数以及检查流程控制参数和零件的频率，以及定期的保养要求。CSA表中的要求和指南将会提醒评估人何时应参考流程表。2 THE COATING SYSTEM ASSESSMENT PROCEDURE 喷涂系统评估程序1.Obtain current copy of CQI-12 Special Process: Coating System Assessment from AIAG. 从AIAG获取“CQI-12 特殊流程：喷涂系统评估”的当前版本。2.Identify all coating processes to which CQI-12 Special Process: Coating System Assessment applies (see CQI-12, 1.2). Record these processes on the CSA. 确认“CQI-12特殊流程：喷涂系统评估”适用的所有喷涂流程（参见CQI-12,1.2）。在CSA上记录这些流程。3.Complete the CSA, determining the level of compliance. A minimum of one job audit(Section 3) shall be performed during each assessment 完成CSA，确定符合程度。应在每次评估期间最少进行一项工作审核（第3部分）。4.Address each “Not Satisfactory” item and determine corrective action, including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. 体现出每个“不令人满意”项目，并确定纠正措施，包括根本原因分析和实施相应的纠正措施。纠正措施应在90天内完成。纠正措施的记录（包括检验）应加以维护。5.“Needs Immediate Action” requires immediate containment of suspect product. Addresseach “Needs Immediate Action” item and determine corrective action(s), including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. “需要立即采取措施”要求立即对可疑产品进行遏制。体现出每个“需要立即采取措施”项目并确定纠正措施，包括根本原因分析和实施相应的纠正措施。纠正措施应在90天内完成。纠正措施的记录（包括检验）应加以维护。6.Assessments shall be conducted annually unless otherwise specified by the customer. 除非客户另有规定，否则评估应每年进行一次。3 SPECIAL PROCESS: COATING ASSESSMENT 特殊流程：喷涂评估INSTRUCTION FOR COMPLETING THE COVER SHEET 完成封面表格的说明. 11COVER SHEET FORM封面表格. 13INSTRUCTIONS FOR COMPLETING SECTIONS 1-2 完成第1和第2部分的说明. 14SECTION 1: MANAGEMENT RESPONSIBILITY & QUALITY PLANNING 第1部分：管理责任及质量规划. 15SECTION 2: FLOOR AND MATERIAL HANDLING RESPONSIBILITY第2部分：场地和材料搬运责任 . 21INSTRUCTIONS FOR COMPLETING THE JOB AUDIT完成工作审核的说明. 25SECTION 4: JOB AUDIT 第3部分：工作审核. 26Instructions for completing the Cover Sheet 完成封面表格的说明1.Facility Name: Name of the facility being assessed. 设施名称：接受评估的设施名称。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 Coating Specialist) or different management system, then these locations shall be considered as separate facilities. 每个设施各用一张表格。设施可拥有数幢建筑或是在同一大致地区拥有多个实体地点。如果有独立的管理团队（质量经理和喷涂专家）或不同的管理体系，则这些地点应被视为独立的设施。2.Address: The street address of the facility being assessed; P.O. Box numbers may be given as additional information.地址：接受评估设施的街道地址，邮箱号码可作为附加信息提供。3.Phone Number: The phone number of the facility. 电话号码；设施的电话号码。If there is no common phone numbe