CQI-11 审核表

1、CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07Special Process: Plating System Assessment /特特别别过过程程：电电镀镀系系统统评评估估Facility Name/工厂名称:Address/地址:Phone Number/电话:Type(s) of Plating Processing at this Facility:工工厂厂电电镀镀工工艺艺类类型型Fax Number/传真:Process Table A/过过程程表表A AZinc/锌Number of P

2、lating Employees at this Facility:工厂员工数Zinc Alloy Plating/镀锌合金Captive Plater (Y/N):Process Table B/过过程程表表B BCommercial Plater (Y/N):Surface Conditioning ofMetals for Decorative Plating/装饰用电镀金属表面条件Date of Assessment/评估日期:Process Table C/过过程程表表C CSurface Conditioning of ABS& PCABS Plastics forDeco

3、rative Plating/装饰用电镀ABS&PCABA塑料表面条件Date of Previous Assessment/上一次的评估日期:Process Table D/过过程程表表D DDecorative Plating/装饰用电镀Process Table E/过过程程表表E EMechanical Plating/机械喷镀Process Table F/过过程程表表F FEquipment/设备Process Equipment/过程设备Current Quality Certification(s):/目前的质量证明Date of Re-assessment (if n

4、ecessary):再评估日期（如需要）Personnel Contacted:/联联系系人人Name/姓姓名名Title:职职位位Phone:电电话话Email;Auditors/Assessors:评评审审员员/评评估估员员Name:姓姓名名Company:公公司司Phone:电电话话Email:Number of Not Satisfactory Findings:不不满满意意项项数数量量Number of Needs Immediate Action Findings:需需立立即即改改善善项项数数Number of Fail Findings in the Job Audit(s):不

5、不合合格格项项数数CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07Special Process: Plating Process Assessment (General Facility Overview整整个个工工厂厂的的评评述述) AssessmentQuestionNumber问问题题编编号号Question/问问题题Requirements and Gui

6、dance/要要求求与与指指南南Objective Evidence/客客观观证证据据N/ASatisfactory/满满意意NotSatisfactory/不不满满意意Needs ImmediateAction/需需立立即即采采取取措措施施Section 1 - Management Responsibility and Quality Planning/管管理理职职责责和和质质量量计计划划1.1Is there a dedicated andqualified plating person on-site?/现场是否配备有资格的电镀员工？To ensure readily availabl

7、e expertise, there shall bea dedicated and qualified plating person on the site.This individual shall be a full-time employee and theposition shall be reflected in the organization chart.A job description shall exist identifying thequalifications for the postition including chemicaland plating knowl

8、edge. The qualifications shallinclude a minimum of 5 years experience in platingand surface finishing or a combination of formalchemistry/chemical engineering education andplating experience totaling a minimum of 5 years.为充分保证可使用的专业技术，现场应配备专职并有资质的电镀人员。此人员必须是位全职，并且职位应在组织图中体现。工作描述必须确定此职位涉及的化学和电镀知识的资质。

9、资质必须包括至少5年在电镀和表面处理方面的从业经验，或正规化学/化学工程专业教育并且在电镀领域至少从业5年的工作经历。1.2Does the plater performadvanced quality planning?是否进行电镀的先期质量策划？The organization shall incorporate a documentedadvance quality planning procedure. A feasibilitystudy shall be performed and internally approved foreach part. Similar parts ca

10、n be grouped into partfamilies for this effort as defined by the organization.After the part approval process is approved by thecustomer, no process changes are allowed unlessapproved by the customer. The plater shall contactthe customer when clarification of process changesis required. This clarifi

11、cation of process changesshall be documented.组织必须结合文件化的先期质量策划的程序。针对每个零件必须进行可行性分析并获得内部批准。相似零件能够组成零件族得到组织定义。PPAP以后，除非顾客批准，否则不允许过程更改。当申明需要过程更改时，电镀商必须联系顾客。过程更改申请必须被文件化。CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07Special Process: Plating Process Assessment (General Facility Over

12、view整整个个工工厂厂的的评评述述) AssessmentQuestionNumber问问题题编编号号Question/问问题题Requirements and Guidance/要要求求与与指指南南Objective Evidence/客客观观证证据据N/ASatisfactory/满满意意NotSatisfactory/不不满满意意Needs ImmediateAction/需需立立即即采采取取措措施施1.3Are plater FMEAs up to dateand reflecting currentprocessing?/电镀FMEA是否更新，并反应了最新过程。The organi

13、zation shall incorporate the use of adocumented Failure Mode and Effects Analysis(FMEA) procedure and ensure the FMEAs areupdated to reflect current part quality status.The FMEA shall be written for each part or partfamily or they may be process-specific and writtenfor each process. In any case, the

14、y shall addressall process steps from part receipt to part shipmentand all key plating process parameters as definedby the organization. A cross-functional team shallbe used in the development of the FMEA. Allcharacteristics, as defined by the organization andits customers, shall be identified, defi

15、ned, andaddressed in the FMEA.组织必须使用文件化的FMEA程序，并确保FMEAs得以更新，以反应当前零件质量状态。必须按每个零件或零件族来编写FMEA，或者他们是某个具体的过程并按照每个过程编写。任何情况下，FMEA必须体现从零件接收到发运的所有过程步骤，以及组织定义的所有关键电镀过程参数。必须由跨功能小组制定FMEA。所有组织和其顾客定义的特殊特性必须在FMEA中得以识别，定义和体现。 1.4Are finish process controlplans up to date andreflecting current processing?是否完成最新的过程控

16、制计划并反应最新过程The organization shall incorporate the use of adocumented Control Plan procedure and ensure theControl Plans are updated to reflect currentcontrols. The Control Plans shall be written foreach part or part family or they may be process-specific and written for each process. In any case,they

17、 shall address all process steps from partreceipt to part shipment and identify all equipmentused and all key plating process parameters asdefined by the organization. A cross-functionalteam, including a production operator, shall be usedin the development of Control Plans, which shall beconsistent

18、with all associated documentation suchas work instructions, shop travelers, and FMEAs.All special characteristics, as defined by theorganization and its customers, shall be identified,defined, and addressed in the Control Plans.Sample sizes and Frequencies for evaluation ofprocess and product charac

19、teristics shall also beaddressed consistent with the minimumrequirements listed in the Process Tables.组织必须结合使用文件化的控制计划程序，并确保控制计划得到更新以反映当前的控制方法。 必须按每个零件或零件族来编写FMEA，或者他们是某个具体的过程并按照每个过程编写。必须按每个零件或零件族来编写FMEA，或者他们是某个具体的过程并按照每个过程编写。任何情况下，FMEA必须体现从零件接收到发运的所有过程步骤，以及组织定义的所有关键电镀过程参数和所使用的设备。必须由包括操作者在内的跨功能小组来制定

20、控制计划。并且与所有的相关文件，如作业指导书，流转卡，和FMEA保持一致。针对过程和产品特性评估的样本大小和抽样频率必须与过程表中列出的最低要求保持一致。CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07Special Process: Plating Process Assessment (General Facility Overview整整个个工工厂厂的的评评述述) AssessmentQuestionNumber问问题题编编号号Question/问问题题Requirements and Guida

21、nce/要要求求与与指指南南Objective Evidence/客客观观证证据据N/ASatisfactory/满满意意NotSatisfactory/不不满满意意Needs ImmediateAction/需需立立即即采采取取措措施施1.5Are all plating related andreferenced specificationscurrent and available? Forexample: SAE, AIAG, ASTM,General Motors, Ford, andDaimlerChrysler. /所有与电镀相关和参考规范是否为最新的和适用的？例如：SAE，AI

22、AG，ASTM，通用公司，福特，戴姆勒克莱斯勒等。To ensure all customer requirements are bothunderstood and satisfied, the organization shallhave all related plating and customer referencedstandards and specifications available for use and amethod to ensure that they are current. Suchstandards and specifications include, b

23、ut are notlimited to, those relevant documents published bySAE, AIAG, ASTM, General Motors, Ford, andDaimlerChrysler. The organization shall have aprocess to ensure the timely review, distribution,and implementation of all customer and industryengineering standards and specifications andchanges base

24、d on customer-required schedule.This process shall be executed as soon as possibleand shall not exceed two weeks. The organizationshall document this process of review andimplementation, and it shall address how customerand industry documents are obtained, how they aremaintained within the organizat

25、ion, how the currentstatus is established, and how the relevantinformation is cascaded to the shop floor within thetwo-week period. The organization shall identify whois responsible for performing these tasks.为确保所有的顾客要求被理解并得到满足，组织必须拥有适用的与电镀相关和顾客参考的标准和规范，并确保它们是最新版本。这些标准和规范包括，但不限于SAE，AIAG，ASTM，通用汽车，福特

26、汽车和戴姆勒克莱斯勒汽车出版的相关文件。组织具备一个流程，确保及时评审，分发，和执行所有的顾客和行业工程标准及规范，并按顾客要求的进度进行更新。此过程必须尽快执行不超过两周。组织必须对评审和实施过程文件化，文件必须体现必须记录如何获得顾客和行业文件，如何在组织内保存，如何保持最新状态，以及如何在两周时间内将相关信息传递到现场。组织必须确认谁来负责完成这些工作。1.6Is there a written processspecification for all activeprocesses? 对所有操作过程是由具备书面的过程规范？The plater shall have written pr

27、ocess specificationsfor all active processes and identify all steps of theprocess including relevant operating parameters.Examples of operating parameters include processtemperatures, cycle times, load rates, rectifiersettings, etc. Such parameters shall not only bedefined, they shall have operating

28、 tolerances asdefined by the organization in order to maintainprocess control. All active processes should have awritten process specification. These processspecifications may take the form of workinstructions, job card, computer-based recipes, orother similar documents. 电镀商必须为所有操作过程和识别的过程步骤建立书面的过程规

29、范，包括相关的操作参数。操作参数包括：过程温度，循环时间，装载率，整流器设置等。组织必须定义这些参数的操作公差以保持过程控制。所有现行过程必须具备书面的过程规范。它们可采用工作指导书，作也卡，计算机系统的参数设定，或其他相似的文件格式。CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07Special Process: Plating Process Assessment (General Facility Overview整整个个工工厂厂的的评评述述) AssessmentQuestionNumber问问

30、题题编编号号Question/问问题题Requirements and Guidance/要要求求与与指指南南Objective Evidence/客客观观证证据据N/ASatisfactory/满满意意NotSatisfactory/不不满满意意Needs ImmediateAction/需需立立即即采采取取措措施施1.7Has a valid product capabilitystudy been performed initiallyand after process change?/生产初始阶段和过程更改后是否进行有效的能力验证？To demonstrate each process

31、 is capable of yieldingacceptable product the organization shall performproduct capability studies for the initial validation ofeach process, after relocation of any processequipment, and after a major rebuild of anyequipment. The organization shall define whatconstitutes a major rebuild. Initial pr

32、oduct capabilitystudies shall be conducted for all plating processesper line as defined in scope of work and inaccordance with customer requirements. Capabilitystudy techniques shall be appropriate for the platingproduct characteristics, e.g. plate thickness,corrosion resistance, etc. Any specific c

33、ustomerrequirements shall be met. In the absence ofcustomer requirements, the organization shallestablish acceptable ranges for measures ofcapability. An action plan shall exist to address thesteps to be followed in case capability indices falloutside customer requirements or establishedranges. 为证明过

34、程有能力生产出合格产品，组织必须为每个过程初始验证，过程设备重新布置，以及任何设备大修之后进行产品能力研究。组织必须定义什么是大修。必须对工作范围内定义的每条生产线的所有电镀过程进行初始能力研究，并与客户要求一致。能力研究技术必须适合电镀产品特性，如：电镀厚度，耐蚀性等。任何顾客特殊要求必须满足，当没有顾客特殊要求时，必须建立测量能力的接受准则。当能力指数超过顾客要求或确定的范围，必须制定行动计划体现后续的措施。1.8Does the plater collect andanalyze data over time, andreact to this data?电镀商是否随时收集分析数据并对此

35、作出反应？The analysis of products and processes over timecan yield vital information for defect preventionefforts. The organization shall have a system tocollect, analyze, and react to product or processdata over time. Methods of analysis shall includeongoing trend or historical data analysis of special

36、product or process parameters. The organizationshall determine which parameters to include insuch analysis.产品和过程数据分析能够为缺陷预防提供重要信息。组织必须具备一个系统随时收集，分析和反应产品和过程数据。分析方法包括对特殊产品或过程参数的现行趋势和历史数据的分析。组织必须确定哪些参数需要列入分析范围。1.9Does management reviewand verify bake oven logs forparts requiring hydrogenembrittlement r

37、elief every 24hours? 管理者是否评审并检查Management shall review the oven monitoringsystems/logs at intervals not to exceed 24 hours orprior to parts being released for shipment. Theplater shall have reaction plans for non-conformances to process requirements. This is tocontain, at minimum, requirements for q

38、uarantiningmaterial and notifying customer.管理者必须每24小时或产品发运前内评审烤炉监控系统/点检日志。 电镀商必须针对不符合过程要求的情况制定反应计划。作为最低要求，应隔离材料并通知顾客。CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07Special Process: Plating Process Assessment (General Facility Overview整整个个工工厂厂的的评评述述) AssessmentQuestionNumber问问题

39、题编编号号Question/问问题题Requirements and Guidance/要要求求与与指指南南Objective Evidence/客客观观证证据据N/ASatisfactory/满满意意NotSatisfactory/不不满满意意Needs ImmediateAction/需需立立即即采采取取措措施施1.10Are internal assessmentsbeing completed on anannual basis, at a minimum,incorporating AIAG PSA? 是否按AIAG PSA 每年至少进行1次内部审核？The organization

40、 shall conduct internalassessments on an annual basis, at a minimum,using the AIAG PSA. Concerns shall be addressedin a timely manner.组织必须使用AIAG PSA，每年最少进行一次内部审核。应及时解决审核时发现的问题。1.11Is there a system in place toauthorize reprocessing and isit documented?/是否有一个文件化的返工批准系统？The quality management system s

41、hall include adocumented process for reprocessing that shallinclude authorization from a designated individual.The reprocessing procedure shall describe productcharacteristics for which reprocessing is allowed aswell as those characteristics for which reprocessingis not permissible. All reprocessing

42、 activity shallrequire a new processing control sheet issued byqualified technical personnel denoting thenecessary plating modifications. Records shallclearly indicate when and how any material hasbeen reprocessed. The Quality Manager or adesignee shall authorize the release of reprocessedproduct.质量

43、管理系统必须包括一个文件化的返工过程，包括对指定人的授权。返修程序必须描述哪些产品特性允许返工，哪些产品特性不允许返工。所有返工活动需要由有资格的技术人员分发一个新的过程控制单，表明电镀更改的必要性。记录必须清楚指明何时，有多少材料被返工。质量经理或指派的授权人员应批准返工产品的发运1.12Does the Quality Departmentreview, address, anddocument customer andinternal concerns? 针对顾客和内部关注的问题，质量部分是否评审，处理并形成文件？The quality management system shall i

44、nclude aprocess for documenting, reviewing, and addressingcustomer concerns and any other concerns internalto the organization. A disciplined problem-solvingapproach shall be used. 质量管理体系必须包括一个针对文件化，评审和解决顾客和组织内部关注问题的过程。可采用问题解决方法。1.13Is there a continualimprovement plan applicableto each process defi

45、ned inthe scope of theassessment? 是否针对审核范围内的每个过程，建立了适用的持续改进计划？The plater shall define a process for continualimprovement for each plating process identified inthe scope of the PSA. The process shall bedesigned to bring about continual improvement inquality and productivity. Identified actions shall

46、beprioritized and shall include timing (estimatedcompletion dates). The organization shall showevidence of program effectiveness. 电镀商必须建立一个持续改进过程，适用于PSA范围中确定的每一个电镀过程。此过程的设计必须致力于质量和生产率的提高。行动计划必须体现优先顺序和日期要求（完成时间）组织必须提供项目有效性运行的证据。CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07Spe

47、cial Process: Plating Process Assessment (General Facility Overview整整个个工工厂厂的的评评述述) AssessmentQuestionNumber问问题题编编号号Question/问问题题Requirements and Guidance/要要求求与与指指南南Objective Evidence/客客观观证证据据N/ASatisfactory/满满意意NotSatisfactory/不不满满意意Needs ImmediateAction/需需立立即即采采取取措措施施1.14Does the Quality Manager or

48、designee authorize thedisposition of material fromquarantine status? /质量管理者或指定人是否批准对隔离材料进行处置？The Quality Manager or designee is responsible forauthorizing and documenting appropriate personnelto disposition quarantine material.质量管理者或指定人员负责批准和文件规定适当的人员对隔离材料进行处置 1.15Are there procedures or workinstruc

49、tions available toplating presonnel that definethe plating process?/ 是否为电镀操作人员准备程序或作业指导书以描述电镀工艺？There shall be procedures and work instructionsavailable to plating personnel covering the platingprocess. These procedures or work instructionsshall include methods of addressing potentialemergencies (su

50、ch as power failure), equipmentstart-up, equipment shut-down, product segregation(See 2.8), product inspection, and general operatingprocedures. These procedures or work instructionsshall be accessible to shop floor personnel.必须建立覆盖电镀过程的，适用的程序和作业指导书。这些程序或作业指导书必须包括处理潜在应急事件的方法（如动力中断），设备开动，停机，产品隔离，产品检验

51、，和一般的操作程序。这些程序或作业指导必须易于现场操作人员获取。1.16Is management providingemployee training for plating?管理层是否为电镀人员提供培训？The organization shall provide employee training forall plating operations. All employees, includingbackup and temporary employees, shall be trained.Documented evidence shall be maintained showing

52、the employees trained and the evidence shallinclude an assessment of the effectiveness of thetraining. Management shall define the qualificationrequirements for each function, and ongoing orfollow-up training shall also be addressed.组织必须为所有从事电镀操作的员工提供培训。所有职工，包括后备员工和临时工。 必须保持文件化的证据证明员工得到了培训并进行了有效性评估。

53、管理层必须确定每项活动的资质要求，及现在和将来的培训需求。1.17Is there a responsibilitymatrix to ensure that all keymanagement and supervisoryfunctions are performed byqualified personnel?/是否有责任矩阵以保证所有关键的管理和监控活动由有资格的人员完成？The organization shall maintain a responsibilitymatrix identifying all key management andsupervisory functio

54、ns and the qualified personnelwho may perform such functions. It shall identifyboth primary and secondary (backup) personnel forthe key functions (as defined by the organization).This matrix shall be readily available tomanagement at all times.组织必须保持责任矩阵来确定所有关键管理和监职能，同时这些职能由有资格的人员完成。对关键职能（组织定义的），应规定

55、主要和次要的人员。管理层能在任何时候易于获取该矩阵CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07Special Process: Plating Process Assessment (General Facility Overview整整个个工工厂厂的的评评述述) AssessmentQuestionNumber问问题题编编号号Question/问问题题Requirements and Guidance/要要求求与与指指南南Objective Evidence/客客观观证证据据N/ASatisfac

56、tory/满满意意NotSatisfactory/不不满满意意Needs ImmediateAction/需需立立即即采采取取措措施施1.18Is there a preventivemaintenance program? Ismaintenance data beingutilized to form a predictivemaintenance program? /是否有预防性维护计划？预防性维护数据是否用于预计性维护项目的输入？The organization shall have a documentedpreventive maintenance program for key

57、processequipment (as identified by the organization). Theprogram shall be a closed-loop process that tracksmaintenance efforts from request to completion toassessment of effectiveness. Equipment operatorsshall have the opportunity to report problems, andproblems shall also be handled in a closed-loo

58、pmanner. Company data, e.g., downtime, qualityrejects, first time-through capability, recurringmaintenance work orders, and operator-reportedproblems, shall be used to improve the preventivemaintenance program. Maintenance data shall becollected and analyzed as part of a predictivemaintenance progra

59、m. 针对关键过程设备（组织定义的），组织必须具备一个文件化的预防性维护程序。该程序必须是一个从请求到实施到有效性评估的闭环，操作者有机会报告问题并在闭环中解决问题。公司数据，如：停机，质量拒收，FTT能力，重复维修工作单，操作者报告的问题均可用来改善预防性维护。必须收集和分析维护数据，使之成为预计性项目的一部分。1.19Has the plater developed acritical spare part list and arethe parts available tominimize productiondisruptions?电镀商是否制订关键零部件备件清单，最小程度减少生产中断

60、？The plater shall develop and maintain a criticalspare parts list and shall ensure the availability ofsuch parts to minimize production disruptions.电镀商必须建立和保持一份关键零部件备件清单，以这些部件最小程度减少生产中断。CQI-11Special Process: Plating System Assessment Version 1 Issued 8/07Special Process: Plating Process Assessment (General