CQI-15-特殊过程：焊接系统评估

1、Special Process: Welding System Assessment特特殊殊工工艺艺：焊焊接接系系统统评评估估Facility Name工厂名称:Address地址:Phone Number电话:Fax Number传真:Number of Welding Employees at this Facility工厂焊接工人总数:Captive WeldOrganization (Y/N)专用焊接工厂（是/否）Commercial WeldOrganization商业焊接工厂（是/否）Date of Assessment: 评估日期Date of PreviousAssessmen

2、t:历年评估日期Current Quality Certification(s) 现有质量体系认证Date of Re-assessment (if necessary): 再次评估日期（如有必要）Personnel Contacted:联联系系人人员员Name:姓姓名名Title:职职务务Auditors/Assessors:审审核核员员/评评估估员员Name:姓姓名名Name:姓姓名名Number of Not Satisfactory Findings“不不理理想想”项项目目数数Number of Needs Immediate Action Findings“需需要要立立即即改改进进”

3、项项目目数数Number of Fail Findings in the Job Audit(s)工工作作审审核核中中“不不合合格格”项项目目数数 2010 Automotive Industry Action Group (AIAG)Type(s) of Weld Processing at this Facility: 工工厂厂焊焊接接流流程程类类别别Process Table A - Arc Welding流流程程表表A 电电弧弧焊焊Arc Stud/Fastener Welding电弧/紧固件焊接Flux Cored Arc Welding包芯焊条电弧焊Gas Metal Arc We

4、lding气体保护金属极电弧焊Submerged Arc Welding埋弧焊Shielded Metal Arc Welding自动保护金属极电弧焊Plasma Arc Welding等离子弧焊Gas Tungsten Arc Welding气体保护钨极电弧焊Gas Metal Arc Braze Welding气体金属电弧钎焊Process Table B - Resistance Welding流流程程表表B电电阻阻焊焊Resistance Spot Welding接触点焊Projection Welding凸焊Resistance Seam Welding电阻缝焊High-freque

5、ncy Seam Welding高频缝焊Induction Seam Welding感应缝焊Mash Seam Welding滚压电阻缝焊Flash Welding闪光对焊Process Table C - Laser Welding流流程程表表C 激激光光焊焊接接Nd YAG Welding钕激光CO2 Welding二氧化碳Diode Welding二极管Wire Fed 送丝系统Process Table D - Solid State Welding流流程程表表D 固固态态焊焊接接Inertia Friction Welding储能摩擦焊接Direct Drive Friction W

6、elding直接驱动摩擦焊接Friction Stir Welding搅拌摩擦焊接Flash Butt Welding闪光对接焊Resistance Butt Welding电阻对焊Ultrasonic Welding超声波焊接Special Process: Welding System Assessment特特殊殊工工艺艺：焊焊接接系系统统评评估估Facility Name工厂名称:Address地址:Current Quality Certification(s) 现有质量体系认证Date of Re-assessment (if necessary): 再次评估日期（如有必要）Phon

7、e:电电话话 Email;Name:姓姓名名Name:姓姓名名Auditors/Assessors:审审核核员员/评评估估员员S pecial Process: Welding System Assessment特特殊殊过过程程：焊焊接接系系统统评评估估Assessment评评价价QuestionNumber问问题题编编号号Question问问题题Requirements and Guidance要要求求与与标标准准Objective Evidence客客观观证证据据N/A不不适适用用Satisfactory理理想想NotSatisfactory不不理理想想Section 1 - Manage

8、ment Responsibility & Quality Planning第第1 1部部分分 管管理理责责任任与与质质量量策策划划1.1Is there a dedicated and qualifiedtechnical welding person on-site? 现场是否有专门的，具有相关资格的焊接人员？To ensure readily available expertise, there shall be a dedicated and qualifiedwelding person on site. This individual shall be one of the fol

9、lowing: DegreedWelding Engineer, or equivalent science degree, Certified Welding Inspectorfrom approved internationally recognized body, or person agreed uponbetween customer and supplier. This person shall be a full-time employee andthe position shall be reflected in the organization chart. A job d

10、escription shallexist identifying the qualifications for the position including metallurgical andwelding knowledge. The qualifications shall include a minimum of 5 yearsexperience in welding operations or a combination of a minimum of 5 years offormal metallurgical education and welding experience.为

11、了确保能够随时得到专业指导，必须有专门的，具有相关资格的焊接人员在场。他们既可以是已获得学位的焊接工程师或工科学位同等学历，也可以是获得国际公认机构认可的检验或客户和供应商共同商定的人员。此人必须是全职员工，其职责必须在企业组织结构中有所反映。职责描述中必须包括确认该职位所需资历，包括冶金和焊接知识。职业资格应包括至少5年的焊接经验，或接受过正规冶金专业教育和焊接工作经验的总年限不少于5年。1.2Is there a responsibility matrix toensure that all key management andsupervisory functions are perfo

12、rmedby qualified personnel? 是否编制了责任矩阵确保所有关键管理职能和监控职能由具有相关资质的人员行使？The organization shall maintain a responsibility matrix identifying all keymanagement and supervisory functions and the qualified personnel who mayperform such functions. It shall identify both primary and secondary (backup)personnel f

13、or the key functions (as defined by the organization). This matrixshall be readily available to management and customer at all times. 企业必须有责任矩阵，来确定所有关键管理和监督职能，并且指定由谁来行使这些职能。必须明确首要和后备人员行使关键职能（由企业界定），该矩阵必须随时供管理部门和客户使用。1.3Do you use only qualified welders(personnel)? 是否所有焊工（人员）都具有具备相关资质？The organizatio

14、n shall provide employee training for all welding operationsspecific to their job function. All welding employees, including backup andtemporary employees, shall be trained. Documented evidence shall bemaintained showing the employees were trained; the evidence shall includean assessment of the effe

15、ctiveness of the training, must prove knowledge ofthe customers specific requirements and internal standards, and whereappropriate, employee certification, such as for a manual welder.Management and customer shall define the qualification requirements for eachfunction and ongoingor follow-up trainin

16、g shall also be addressed. 部门应向雇员提供所有焊接操作方面与其具体工作相关的培训。所有焊工，包括后备人员和临时雇员，都应接受培训。已记录在案的证据应加以维护，表明雇员已接受了培训，其中应包括对培训有效性的评估，且应证明了解客户的具体要求和内部标准，在必要的情况下，应提供雇员资助证明，如手工焊工。管理层和客户应规定每项职能的资质要求，还应列出现行或后续的培训。1.4How do you maintain weldercertification? 如何维护焊工认证？Required qualification maintenance. If the welder has

17、 not welded in thespecific operation in a 6 month time frame, the welder must be requalified tothat operation. Based on the welders quality performance, it must beestablished when retraining and requalification of the individual must beperformed. 所需的资质维护。如果焊工在6个月的时间内没有从事具体的焊接操作，该焊工必须重新取得该种操作的认证。应根据焊

18、工的质量表现，来确定在何时对其进行再培训并重新获得资质。1.5Is set-up practice in compliance withdocumented work instructions? 设定的实践方案是否符合已文件记录的工作说明?Set-up verification to the procedures (as example: equipment settings,clamping sequence, weld sequence, direction of travel and other processcontrols) in compliance to documented w

19、ork instructions.设置的程序核查（如：设备的设置、夹紧顺序、焊接顺序、移动方向和其他流程控制）符合已文件记录的的工作说明。1.6Does the welding organization performadvanced quality planning? 焊接工厂是否进行过先期质量规划?The organization shall incorporate a documented advance quality planningprocedure. A feasibility study shall be performed and internally approved fo

20、reach part. Similar parts can be grouped into part families for this effort asdefined by the organization. After the part approvalprocess is approved by thecustomer, no process changesare allowed unless approved by the customer.The welding organization shall contact the customer when clarification o

21、fprocess changes is required. This clarification of process changes shall bedocumented. 工厂应整合了一份已文件形式的先期质量规划程序。每个零件都应进行可行性研究并获得内部批准。类似零件可根据工厂规定形成零件系列。在客户批准零件批准流程后，除非经客户批准，否则不得对流程进行更改。当需要有流程更改说明时，焊接工厂应联系客户，应将流程更改说明记录在案。1.7Are welding FMEAs up to date andreflecting current processing? 焊接工厂失效模式及后果分析（FM

22、EA）是否为最新并反映了当前的加工状况？The organization shall incorporate the use of a documented Failure Modeand Effects Analysis (FMEA) procedure and ensure the FMEAs are updatedto reflect current part quality status.The FMEA shall be written for each part orpart family or they may be process-specific and written fo

23、r each process. Inany case, they shall address all process steps from part receipt to partshipment and all key welding process parameters as defined by theorganization. A cross- functional team shall be used in the development ofthe FMEA. All special characteristics, as defined by the organization a

24、ndits customers, shall be identified,defined, and addressed in the FMEA. 部门应整合使用一份已记录在案的失效模式及后果分析（FMEA）程序并确保FMEA会进行更新以反映当前的零件质量状态。应为每个零件或零件族编写FMEA，如果FMEA是依特定流程而定的，则还可针对每个流程进行编写。在任何情况下，FMEA都应体现出从零件接收到零件装运的所有流程步骤，以及部门所规定的所有关键的焊接流程参数。在制订FMEA时，应使用一个跨职能团队。根据部门及其客户的规定，所有特殊特性都应在FMEA中进行识别、定义和体现。1.8Are weldi

25、ng process control plans upto date and reflecting currentprocessing? 焊接工艺控制计划是否为最新并反映了当前的加工状况？The organization shall incorporate the use of a documented Control Planprocedure and ensure the Control Plans are updated to reflect currentcontrols. The Control Plans shall be written for each part or part

26、 family orthey may be process-specific and written for each process. They shalladdress all process steps from part receipt to part shipment and identify allequipment used and all essential welding process parameters as defined bythe relevant individual process tables or non-essential as agreed uponb

27、etween supplier and customer. A cross- functional team, including aproduction operator, shall be used in the development of Control Plans,which shall be consistent with all associated documentation such as workinstructions, shop travelers, and FMEAs. All special characteristics, asdefined by the org

28、anization and its customers, shall be identified, defined,and addressed in the Control Plans. Sample sizes and frequencies forevaluation of process and product characteristics shallalso be addressedconsistent with the minimum requirem ents listed in the Process Tables. 工厂应整合使用一份已记录在案的控制计划程序，并确保控制计划会

29、进行更新以反映当前的控制状态。应为每个零件或每个零件系列编写控制计划，如果控制计划是依特定流程而定的，则还可针对每个流程进行编写。控制计划应体现出从零件接收到零件装运的所有流程步骤、所有使用的设备和相关流程表所规定的所有关键的焊接流程参数，或供应商和客户约定的非关键的焊接流程参数。在制订控制计划时，应使用一个包括生产操作员在内的跨职能团队，控制计划应与所有相关文件相符，如工作指南、工艺流程卡和组织失效模式及后果分析（FMEA）。根据部门及其客户的规定，所有特殊特性都应在控制计划中进行识别、定义和体现。评估流程的抽样规模和频率以及产品特性也应体现出与流程表中所列的最低要求相符。1.9Are al

30、l welding related and referencedspecifications current and available?For example: SAE, AIAG, ASTM,ASME, AWS, ISO, General Motors,Honda, Ford, Toyota and Chrysler. 所有与焊接相关及引用的规范是否为当前可用的最新版本？例如：SAE、AIAG、ASTM、ASME、 AWS、ISO、通用汽车、Honda、福特、丰田和克莱斯勒的标准与规范。To ensure all customer requirements are both underst

31、ood and satisfied, theorganization shall have all specifically related welding and customerreferenced standards and specifications available for use and a method toensure that they are current. Such standards and specifications may include,but are not limited to, those relevant documents published b

32、y SAE, AIAG,ASTM, ASME,AWS, ISO, General Motors, Honda, Ford, Toyota,andChrysler. The organization shall have a process to ensure the timelyreview, distribution, and implementation of all customer and industryengineering standards/specifications and changes based on customer-required schedule. Timel

33、y review should be as soon as possible and shall notexceed two working weeks. The organization shall document this process ofreview and implementation, and it shall address how customer andindustrydocuments are obtained, how they are maintained within the organization,how the current status is estab

34、lished, and how the relevant information iscascaded to the shop floor within the two-week period. The organization shallidentify whois responsible for performing these tasks. 为确保所有客户要求都能得到理解和满足，部门应准备好所有相关的焊接及客户引用的标准与规范以供使用，并拥有一个可确保这些标准与规范都是最新版的方法。这些标准与规范包括但不限于由SAE、AIAG、ASTM、ASME、AWS、ISO、通用汽车、Honda、福

35、特、丰田和克莱斯勒出版发行的有关文件。应有一个流程，可确保能及时地审核、分送和实施所有客户及行业的工程标准与规范，以及根据客户要求的时间表而进行的变更。审核应尽快执行，不得超过2周。部门应将此审核与实施流程记录在案，并应体现出客户和行业文件是如果获得的。该流程在部门内是如何进行维护的，.当前状态是如何建立的、以及相关信息是如何在两周之内层层传达到车间的。部门应明确由谁来负责执行这些任务。1.10Is there a written processspecification for all active processes?对所有现行流程，是否有书面的流程规范？The welding organ

36、ization shall have written process specifications for all activeprocesses and repair processes which identify all steps of the processincluding relevant operating parameters. Examples of operating parameters asdefined by the relevant process tables.Such parameters shall not only bedefined, they shal

37、l have operating tolerances as defined by the organization inorder to maintain process control.These process specifications may take theform of work instructions, job card, set-up sheets, or other similar documents.焊接工厂应拥有所有现行流程和修理流程的书面流程规范， 并明确流程的所有步骤，其中包括.相关的操作参数。操作参数的样例见相关流程表。此类参数不应仅仅是加以规定，还应有工厂所

38、规定的操作公差，以便维持流程控制。这些流程规范可采用工作说明、作业卡、设定设定表单或其他类似文件的形式。1.11Has a valid product capability studybeen performed initially and afterprocess changes? 在生产初始阶段和流程更改后，是否进行了有效的产品生产能力研究？The organization shall perform product capability studies for the initialvalidation of each process, after relocation of any p

39、rocess equipment, andafter a major process change of any equipment or parameter. Theorganization and customer shall define what constitutes a major processchange. Initial product capability studies shall be conducted for all weldingprocesses per each processpath defined in scope of work and in accor

40、dancewith customer requirements. In the absence of customer requirements, theorganization shall establish acceptable ranges for measures of capability. Anaction plan shall exist to address the steps to be followed in case capabilityindices fall outside customer requirements or established ranges.部门应

41、进行产品生产能力研究以便完成对各流程的初次验证，并要在重新安置任何加工设备或对任何设备或参数进行重大过程更改后进行产品生产能力研究。部门和客户应定义何为重大过程更改。应根据工作范围中的规定并按照客户要求，对各工艺路径上的所有焊接流程进行初始产品生产能力研究。当没有客户特定要求时，部门应确立用以衡量生产能力的可接受范围。如果生产能力指数不在客户要求或所确立的范围内，应有一个行动计划来体现出要遵循的步骤。Each process path includes all combinations of equipment that are integratedin the performance of

42、a welding process, e.g., weld cell with A and B sidefixture feeding another weld cell with A and B side fixture or multiplemachines. Capability study techniques shall include boundary sampleconditions as defined by the control plan that are robust and meet allcustomer requirements. Example, any comb

43、ination of tolerances as definedby Process Tables. 每个工艺路径都包括一个焊接流程性能中集成的所有设备组合，如使用A和B夹具进行焊接单元，同时使用另一个A和B夹具或多台设备为另一单元进料。生产能力研究技巧应包括控制计划中规定的边界样本的特性，同时也应达到任何客户特定要求。例如流程表所定义的任何公差组合。1.12Does the welding organization monitorand analyze data over time, and reactto this data? 焊接工厂是否会不时监测和分析数据，并对这些数据做出反应？The

44、 analysis of products or processes over time can yield vital information fordefect prevention efforts. The organization shall have a system to collect,analyze, and react to product or essential process data over time. Methods ofanalysis shall include ongoing trend or historical data analysis of prod

45、uct orprocess parameters. The organization shall determine which parameters toinclude in such analysis. 经常分析产品或流程能够为缺陷预防工作提供重要的信息。工厂应有一个不时收集、分析产品或流程数据并对其做出反应的系统。分析方法应包括对重要产品或流程参数的现行趋势或历史数据分析。工厂应确定要将哪些参数包括在此类分析中。1.13Is management reviewing the weldcontrol system at a frequencydetermined by the contro

46、l plan? 管理层是否按照控制计划规定的频率审查焊接控制系统？Management shall review the weld process control systems. Themanagement review shall include efforts to detect out-of-control conditions oralarm conditions. The process of reviewing the control system shall bedocumented and recorded in the control plan. 管理层应审查焊接流程控制系

47、统。管理层审查应包括检测意外事故或报警条件。审查控制系统的流程应记录在案并在控制计划中予以记录。1.14Are internal assessments beingcompleted on an annual basis, at aminimum, using AIAG WSA? 是否会结合AIAG 的CSA，每年最少进行一次内部评估？The organization shall conduct internal assessments on an annual basis, at aminimum, using the AIAG WSA. Concerns shall be addresse

48、d in a timelymanner. 部门应使用AIAG的CSA，每年最少进行一次内部评估。应及时体现出所发现的问题。1.15Does the Quality Department review,address, and document customer andinternal concerns? 对客户以及部门内部关注的问题，质量部门是否会审核、处理并用文件记录在案？The quality management system shall include a process for documenting,reviewing, and addressing customer concer

49、ns and any other concerns internalto theorganization. A disciplined problem-solving approach shallbe used. 质量管理体系应包括有一个用以记录、审核和处理客户关注问题以及任何其它部门内部关注问题的流程，应使用照章办事的问题解决方法。1.16Is there a continual improvement planapplicable to each process defined inthe scope of the assessment? 是否有适用于评估范围中所规定的各流程的持续改进计划

50、？The welding organization shall define a process for continual improvement fortheir welding processes identified in the scope of the WSA. The continualimprovement process shall be designed to bring about improvements inquality and productivity. Identified actions shall be prioritized and shall inclu

51、detiming (estimated completion dates). The organization shall show evidenceofprogram effectiveness. 焊接部门应为WSA范围中所确定的每个焊接流程规定一个持续改进流程。. 持续改进流程应的设计应能同时带来质量和生产率上的持续改进。流程明确的行动应摆放在优先位置，并应包括有时间安排（预计完成日期）。部门应出示证据，证明行动方案的有效性。1.17Does the Quality Manager ordesignee authorize the disposition ofmaterial from q

52、uarantine status? 质量经理或被指派人是否能授权处置处于隔离状态的材料？The Quality Manager or designee is responsible for authorizing anddocumenting the disposition of quarantined material. 质量经理或被指派人负责授权处置隔离材料，并将此记录在案。1.18Are there procedures or workinstructions available to the weldingpersonnel that define the weldingprocess

53、? 是否向焊接人员提供了规定焊接流程的程序或工作说明？There shall be procedures or work instructions available to welding personnelcovering the welding process. These procedures or work instructions shallinclude methods of addressing potential emergencies (such as power failure),equipment start-up, equipment shut-down, produc

54、t segregation (See 2.8),product inspection, safety, house- keeping, and general operating procedures.These procedures or work instructions shall be accessible toshop floorpersonnel. 应向焊接人员提供涵盖整个焊接流程的程序或工作说明。这些程序或工作说明应包括处理可能发生的紧急情况（如断电）的方法、设备启动、设备关闭、产品隔离（参见2.8）、产品检验、安全、管理以及一般性操作程序。车间工作人员应能获取这些程序或工作说明

55、。1.19Is there a preventive maintenanceprogram? Is maintenance data beingutilized to form a predictivemaintenance program? 是否有预防性的维护方案？是否在利用维护数据来形成一个具有前瞻性的维护方案？The organization shall have a documented preventive maintenance program forprocess equipment (as identified by the Process Tables). The progr

56、am shallbe a closed- loop process that tracks maintenance efforts from request tocompletion to assessment of effectiveness. Equipment operators shall havethe opportunity to report problems, and problems shall also be handled in aclosed-loop manner.Company data, e.g., downtime, quality rejects, first

57、-time-through capability, recurring maintenance work orders, and operator-reportedproblems, shall be used to improve the preventive maintenanceprogram.Maintenance data shall be collected and analyzed as partof apredictive maintenance program. 部门对流程设备（由流程表定义）应有一个已记录在案的预防性维护方案。该方案应是一个跟踪维护措施的闭环流程，从申请到完

58、成再到有效性评估。设备操作人员应有机会报告问题并在闭环中解决问题。公司数据，如停机时间、质量拒收（QR)、一次合格率（FTT)、重复维修工作指令以及操作人员报告的问题，应可用来改善预防性维护方案。维护数据应作为预测性维护方案的一部分，进行收集和分析。1.2Has the welding organizationdeveloped a critical spare part list andare the parts available to minimizeproduction disruptions? 焊接部门是否发展完善了一份关键备件列表，所述零件是否齐备以将生产中断降至最低？The we

59、lding organization shall develop and maintain a critical spare parts listand shall ensure the availability of such parts to minimize productiondisruptions. 焊接部门应发展完善并维护一份关键备件列表，并应确保此类零件的可获性以将生产中断降至最低。1.21How does the organization documentand respond to quality spills,nonconformance, customerconcerns

60、? 部门如何记录质量泄漏、不合规情况以及顾客的关注并做出反应？Reaction plans are to be followed per the control plan and PFMEA or, in thecase of newly indentified issues PFMEA and control plan must be updated toreflect the new failure mode and reaction steps taken.应按照控制计划和PFMEA执行反应计划。如果发现新的问题，应对PFMEA和控制计划进行更新，以反映新的失效模式和所采取的反应措施。1