CQI15 焊接系统评估

1、cqi-15美国汽车工业行动集团special process: welding system assessment特殊过程：焊接系统评估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 redu

2、ce 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

3、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 t

4、he 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 cond

5、uct 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, occup

6、ational 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a

7、n 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 manufactu

8、ring, 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

9、 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 docume

10、nt 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 commit

11、tee 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。march 2010.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 other

12、wise 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 c

13、ontent. 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 automot

14、ive 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

15、车工业行动集团版权所有foreword 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

16、 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

17、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

18、他们表示感谢。acknowledgements致谢core members: 核心成员：joseph beckhamchrysler group llc gilbert chrostowski trw automotive virender choudhri delphi corporation thomas lopiccologeneral motors company neal mcmichael ford motor companycarl occhialinithe lincoln electric companyveronica sebaldtoyota motor engineer

19、ing & manufacturing, north americaryan turnwald honda of america manufacturing, inc. dave willignexteer automotivetable of contents目录about aiag关于aiag.1foreword 前言.3acknowledgements致谢.3table of contents 目录.4introduction简介.5general综述.5process approach 流程步骤.5welding system assessment goals焊接系统评估目标. .5a

20、ssessment process 评估过程. .5assessor qualifications .审核员资格. .6other requirements其他要求. .61 scope范围.71.1 general 综述.71.2 application应用.71.3 reference参考文献.82 the welding system assessment procedure 焊接系统评估过程. .93 special process: welding assessment 特殊过程：焊接评估. . 10appendix a process tables附录a 流程表.31glossar

21、y术语表.49introduction简介general综述the work of preparing cqi-15: special process: welding system assessment (wsa) was carried out through the aiag welding work group. these welding requirements are complementary to customer and product standards. cqi - 15：特殊过程：焊接系统评估 (wsa)的准备工作由aiag焊接工作组完成，这些焊接标准作为客户标准和产

22、品标准的补充要求。the wsa 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 wsa can also be used between an organization and its suppliers. wsa可以用来评估一家企业达到评估标准的能力，也可以是达到客户的要求、行业规定和企业自定的标准。ws

23、a也可以在企业与其供必须商之间使用in the wsa, 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” i

24、s used, any suggestions given are for guidance only. 在wsa中，“必须”一词表明这是一项自我评估的要求。如果未能达到标准，则评估结果显示为“不理想”或“需要立即改进”。“应该”一词表明某项建议。如果在文中出现“比如”一词，则表明下列建议仅供参考。process approach流程步骤the wsa supports the automotive process approach as described in iso/ts 16949. wsa支持iso/ts 16949:2002中描述的汽车流程步骤。welding system ass

25、essment goals焊接系统评估目标the goal of the wsa is the development of a welding management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain. wsa的目标是对焊接管理系统的发展，以提供持续的完善，强调对供必须链中差错的预防，减少波动和浪费the wsa, coupled with an int

26、ernationally recognized quality management system and applicable customer-specific requirements, defines the fundamental requirements for welding management systems. wsa配合国际公认的质量管理系统和使用的客户特定要求，详细说明了对焊接管理系统的基本要求。the wsa is intended to provide a common approach to a welding management system for autom

27、otive production and service part organizations. wsa旨在为汽车生产件和售后服务件公司提供一个共同的焊接管理系统方法。assessment process评估过程ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to re- examine the continuing compliance with the wsa. each assessment shall include a review of the

28、organizations systems using the wsa. successive job audits (section 6.0 of this document) shall sample parts from different automotive component manufacturers that require compliance to the wsa document. 除非客户有特别要求（对wsa要求的符合程度进行再次检查），一般情况下评估过程必须每年进行一次。每次评估必须包括使用wsa对企业系统进行检查。连续工作审核（见本文第六部分）必须采集汽配制造商的零

29、部件样本检测其是否符合wsa的标准。the assessment shall use the process approach to auditing as identified by the requirements of iso/ts16949. 评估必须使用iso/ts 16949 规定的流程步骤来审核/评估。assessor qualifications审核员资格assessor(s) shall have the following specific experience to conduct the welding system assessment: 审核员必须具有下列具体经验，

30、才能来进行焊接系统评估。1. be an experienced quality management system (qms) internal auditor (for example, latest edition of iso/ts 16949, iso 9001) 资深的质量管理系统(qms)内部审核员（比如：iso/ts 16949、iso 9001的最新版）。2. assessor shall possess welding knowledge. evidence shall include a minimum of 5 years experience in welding o

31、r a combination of formal education in welding and welding experience totaling a minimum of 5 years. 审核员必须具有焊接专业知识。包括至少5年的焊接和表面精加工的经验，或接受过正规焊接教育和焊接工作经验的总年限不少于5年。3. assessor shall possess knowledge of and be familiar with the application of automotive quality core tools including statistical process

32、control, measurement systems analysis, part approval, failure mode and effects analysis, and advanced quality planning. 审核员必须具有包括统计过程控制、测量系统分析、零件认可、失效模式和后果分析，以及先期质量策划等汽车质量核心工具的相关知识，并能熟练运用。note: if more than one assessor is required to meet the above qualifications, the lead assessor shall be the per

33、son meeting the requirements in item #1. 如果有多名审核员符合以上要求，则主审员应由最符合以上各条（或第一条）要求的人员担任。other requirements其他要求the organization shall keep records as evidence of compliance to the requirements identified in the wsa, as well as all appropriate action plans to address any unsatisfactory ratings. these recor

34、ds shall be readily available for review by any customer requiring compliance to the requirements within this document. 企业必须保留相关记录，证明已达到wsa标准，同时记录所有为改善不理想的评估项目而采取的适当改进计划。这些记录必须为客户准备，以便客户对记录中的要求的符合情况进行复检。1 scope范围1.1 general综述this document specifies process requirements for an organization or its sup

35、pliers performing applicable welding, who need to: 本文详细说明了企业或其供应商在进行焊接时的流程要求，需要：demonstrate ability to consistently provide product that meets customer and applicable regulatory requirements, and证明具有持续提供符合客户和使用规范标准的产品的能力。enhance customer satisfaction through the effective application of the system,

36、including processes for continual improvement of the system. 通过有效应用系统，包括持续改进系统流程，提高客户满意度。the welding system assessment is applicable to sites where customer-specified parts for production and/or service are processed throughout the automotive supply chain. 焊接系统评估适用于汽车供链中各个加工客户指定的用于生产和/或售后服务的零部件的厂点。1

37、.2 application应用all requirements of the wsa are generic and are intended to be applicable to all organizations performing the welding operations addressed in this document, regardless of type, size, and product. wsa所有的标准都是普遍使用的，适用于所有企业进行本文描述的焊接操作，不论型号、大小和产品的区别。note: four process tables have been dev

38、eloped and the appropriate table(s) is to be referenced during the assessment. the process tables are specific to welding processes as noted below: 注：编写了四张流程表，相应的表格可在评估过程中做参考用。流程表的详细焊接程序如下所示：process table a - arc welding流程表a 电弧焊arc stud/fastener welding 电弧/紧固件焊接flux-cored arc welding 包芯焊条电弧焊gas meta

39、l arc welding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流程表b电阻焊resistance spot welding接触点焊projection welding 凸焊resistance seam welding电阻缝焊high-fr

40、equency 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流程表c 激光焊接nd yag钕激光co2二氧化碳diode 二极管wire fed联邦储备总线process table d - solid state welding流程表d 固态焊接inertia friction welding储能摩擦焊接direct drive friction welding直接驱动摩擦焊接friction stir we

41、lding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these process tables contain requirements for: 这些过程表包含下列要求：1.management responsibility & quality planning管理责任和质量策划2.floor and material handling responsibility工厂与物料处理责任3.equipment / facilities/controls设备/设施/控制4.toolin

42、g/fixturing模具/夹具5.process controls and confirmation过程控制与确认6.essential variables基本变量the process tables specify the tolerances of process parameters and the frequencies for checking process control parameters and parts. the requirements and guidance in the wsa form will notify the assessor when to ref

43、er to the process tables. 流程表规定了参数的公差和检查控制参数与零件的频率。wsa表格中的要求与指南将提示审核员何时应参考流程表。1.3 reference参考文献the following standards are used as reference material. there are other reference materials that contain more information, however, the list is not meant to be inclusive. the applicability is limited to th

44、e subject matter referenced.以下标准作为本文件的参考资料，然而，本文件还引用了其他包含更多信息的参考材料，因此列表并不包含所有参考文献在内，其适用范围仅限于所引用的主题方面。 number标准编号title标准名称standards organization标准发布机构ansi z 49.1safety in welding and cutting焊接与切割安全ansi - aws a3.0standard welding terms anddefinitions标准焊接术语和定义aws c7.2recommended

45、practices forlaser beam and welding激光束焊接推荐规程2the welding system assessment procedure焊接系统评估过程1.obtain current copy of cqi-15 special process: welding system assessment, from aiag. 从aiag获取最新的cqi-15 特殊过程：焊接系统评估。2.identify all welding processes to which cqi-15 special process: welding system

46、assessment, applies (see cqi-15, 1.2). record these processes on the wsa. 确认cqi-15 特殊过程：焊接系统评估所使用的焊接流程。将这些流程记录在wsa第一页上。3.complete the wsa, determining the level of compliance. a minimum of one job audit(section 6) shall be performed during each assessment. 完成wsa，确定符合度。每次评估必须至少由一名工作审核员（第六部分）进行。4.addr

47、ess 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. 分析每

48、一个“不理想”的环节，并确定正确的行动方案，包括分析问题根源，并执行相应的纠正措施。纠正措施必须在90天内完成。有关记录，包括验证记录必须收录在案。5.“needs immediate action” requires immediate containment of suspect product. address each “needs immediate action” item and determine corrective action(s), including root cause analysis and implementation of the corresponding

49、 corrective action(s). the corrective action(s) shall be completed within 90 days. records of the corrective action, including verification, shall be maintained. “需要立即改进”表示要求立刻保留问题产品。解决每一个“需要立即改进”的环节，并确定正确的行动方案，包括分析问题根源，并执行相应的纠正措施。纠正措施必须在90天内完成。有关记录，包括验证记录必须收录在案。6.assessments shall be conducted annually unless otherwise specified by the customer. 除非客户另有要求，评估必须每年进行一次。3 special