Automate Indust Acton Geup CQI-15 Special Process: Welding System Assessment FOR REFERENCE ONLY Verify Revision @ www.aiag.orgw o oO AIAG gauss Vosine 1 Issube 36 ABOUT AIAG Purpose Statement 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. AIAG's goals are to reduce cost and ‘complexity through collaboration; improve product quality, health, safely and the environment: and optimize speed to market throughout the supply chain, AIAG Organization AIAG is made up of a board of directors, an executive director, executives on loan from member companies, associate directors, a fulltime staff, and volunteers serving on project teams. Directors, department managers, and program managers plan, direct and coordinate the association's activities Under the direction of the executive director. AIAG Projects Volunteer committees focus on business processes or supporting technologies and methodologies. They conduct research and develop, publish, and provide training on standards, conventions, standard business practices, white papers, and guidelines in the areas of automatic identification, CAD/CAM, EDl/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. ‘AIAG PUBLICATIONS {An AIAG publication reflects a consensus ofthese substantially concemmed with ts Scope and provisions. An AIAG publication is intended as @ guide to aid the manufacturer, the consumer and the general pu. The ‘existence of an AIAG publication does not in any respect preclide anyone from manufacturing, marketing, | purchasing, oF using products, processes, or procedures hot conforming tothe publ ator i | cautionary Novice | AIAG publications are subject to penodic review and users are cautioned fo obtain the latest edtions | | | MAINTENANCE PROCEDURE Recognizing that this AIAG publication may not cover ail citcumstances, AIAG has established a maintenance | | procedure Piease refer the Maintenance Request Form atthe back. ofthis document to submiarequest, | Published by: | ‘Automotive Industry Action Group 26200 Lahser Road, Suite 200, ‘Southfield, Michigan 48033 Phone: (248) 358-3570 » Fax: (248) 388.9253 ‘APPROVAL STATUS The AIAG Quaity Steering Commitee and designated stakeholders approved this document for publication in | Maren 2010 AIAG COPYRIGHT AND TRADEMARK NOTICE: © 2010 Automotive industry Action Group. except that copyngh snot claimed as fo any part ofan original work prepared by a U.S. ‘or stale government officer or employee as part of the person's offal duos Except as noted above, alight are reserved by AIAG and no part ofthese materials may be reproduced. reprinted, stored in 2 retrieval system, or transmited. i any fom or By any means, electron. photocopying, recording. or otherwise tte plot \wotten permission of Aulomotive Industry Action Group. Copynghtenringerent sa ulation of lederal law sutject to criminal anc evi ponaties [AIAG ant Automotive Industry Action Group ave registered service marks ofthe Automot 1 Action Grou. Automotive Industry Acton Group makes no claim to any Wademark ofa fird pay Trademarks of third partes included in these materals are the property af ther respecive owners, 2010 Automoove Indust Aetion Group ISBN 975 1 60534 208 5caus AIAG 2m ‘Version 1 issued 3/10AIAG 2» cals FOREWORD Automotive Industry Action Group (AIAG) commitiges are made up of valunteers from member companies in the automotive industry. The work of preparing process audits is done by AIAG technical committees. The main task of technical committees is to prepare Automotive Standards and System Requirements Drafi 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, 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, ACKNOWLEDGEMENTS wre Members: Joseph Beckham Chrysler Group LLC Gilbert Chrostowski TRW Automotive Virender Choudhri Delphi Corporation Thomas Lopiccolo General Motors Company Neal MeMichael Fotd Motor Company Catt Gechialini The Lincoln Electric Company Veronica Sebald Toyota Motor Engineering & Manufacturing, North America Ryan Turnwald Honda of America Manufacturing. Inc Dave Willig Nexteer Automotivecaus AIAG Version 1 Issued 3/10 Audorenncaty Aten Gio TABLE OF CONTENTS ABOUT AIAG. FOREWORD. ACKNOWLEDGEMENTS... TABLE OF CONTENTS. INTRODUCTION Generac é PROCESS APPROACH s 5 5 WELDING SYSTEM ASSESSMENT Goals, ASSESSMENT PROCESS . 3 [ASSESSOR QUALIFICATIONS 6 OTHER REQUIREMENTS, 6 1 SCOPE... LA GENERAL 7 12 AppLication i 13 ReFERENcr ‘ 2 THE WELDING SYSTEM ASSESSMENT PROCEDURE 3 SPECIAL PROCESS: WELDING ASSESSMENT APPENDIX A ~ PROCESS TABLES GLOSSARY. AAAR-~ @ G @ aAIAG Gauss INTRODUCTION General The work of preparing CQI-IS: Special Process: Welding System Assessment (VSA) was carried out through the AIAG Welding Work Group. These welding requirements are complementary to customer and product standards s in this assessment. as can also be used The WSA can be used to assess an organization's ability to meet the requireme well as customer. regulatory, and the organization's own requirements. The WS between an organization and its suppliers. 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” ot “Needs Immediate Action.” ‘The word “should” indicates a recommendation, Where the term “such as” is used, any suggestions given are for guidance only. Process Approach The WSA supports the automotive process approach as described in ISO/TS 16949. Welding System Assessment Goals 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. The WSA, coupled with an intemationally recognized quality management system and applicable defines the fundamental requirements for welding management systems. ceustomer-specific requirement The WSA is intended to provide a common approach to a welding management system for automotive produetion and service part organizations. Assessment Process 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 ‘organization's systems using the WSA. Successive Job Audits (Section 6.0 of this document) shall sample parts ftom different automotive component manufacturers that require compliance to the WSA document. The assessment shall use the process approach to auditing as identified by the requirements of ISO"TS 16949,oats AIAG Version 1 Issued 3710 Automat ndusy Acton Group Assessor Qualifications or(s) shall have the following specific experience to conduct the WE! MENT: 1, Bean experienced quality management system (QMS) internal auditor (for example, latest edition of ISO'TS 16949, 180 9001) 2. Assessor shall possess welding knowledge, Evidence shall include a minimum of 5 years experience in welding or a combination of formal education in welding and welding experience totaling a minimum of S years 3. Assessor shall possess knowledge of and be familiar with the application of automotive quality core tools including statistical process control, meastirement systems analysis, part approval, failure mode and effects analysis, and advanced quality planning. sor is required to meet the above sor shall be the person meeting the | Note: If more than one asst qualifications, the lead a | requirements in item #1 Other Requirements ‘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 records shall be readily available for review by any customer requiring compliance to the requirements within this document. ARaAr” ~8@ec an--AIAG» caLts 1 SCOPE 1.1 General This document specifies process requitements for an organization or its suppliers performing applicable welding, who need to: © demonstrate ability to consistently provide product that meets customer and ements, and applicable regulatory regu ‘+ enhance customer satisfaction through the effective application of the system. including processes for continual improvement of the system, The Welding System Assessment is applicable o sites where customer-specified parts for production and/or serviee are processed throughout the automotive supply chain, 1.2 Application 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. te: Four Process Tables have been developed and the appropriate table(s) into be referenced during the assessment. The Process Tables are specific to welding processes as noted below: Process Table A - Are Welding Are Stud Fastener Welding Flux-Cored Are Welding Gas Metal Are welding Submerged Are Welding Shielded Metal Are Welding Plasma Are Welding Ga Uungsten Arc Welding Gas Metal Are Braze Welding Process Table B - Resistance Welding Resistance Spot Welding Projection Welding Resistance Seam Welding High-Frequency Seam Welding Induction Seam Welding Mash Seam Welding Flash Weldingcoe AIAG ‘Special Process: Welding Systom Assessment | Version 1 Issued 3/10 Ausemotive indy 00 Group Process Table C - Laser Weldin, Nd YAG coz DIODE Wire Fed Inertia Friction Welding Direct Drive Friction Welding Friction Stir Welding Flash Butt Welding Resistance Butt Welding Ultrasonic Welding ‘These Process Tables contain requirements for: Management Responsibility & Quality Planning Floor and Material Handling Responsibility Equipment / Facilities/Controls Tooling Fixturing Process Controls and Confirmation Essential Variables 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 refer to the Process Tables. 1.3 Reference The following standards are used as reference material. There are other reference materials that contain the ist is not meant to be inclusive, The applicability is limited to the subject more information, howevei matter referenced. Sens io Ser ed Welding and Cutting | ANSI - ww AWS A30 ~ | Standard Welding Terms and | www.awso - finitions fawsc72 commended Practices for | wwwawsorg | Laser Beam and Welding “aagarlaa Oo AIAG cans 2 I THE WELDING SYSTEM ASSESSMENT PROCEDURE Obtain current copy of COM-15 Special Process: Welding System Assessment, from AIAG. Process: Welding System Assessment. Identify all welding processes to which COI-15 Speci applies (see CQI-I5, 1.2), Record these processes on the WSA. Complete the WSA, determining the level of compliance. A minimum of one job audit (Section 6) shall be performed during each assessment Address each “Not Satisfactory” item and determine corrective action, including root cause analy'sis 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 “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 corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained, Assessments shall be conducted annually unless otherwise specified by the customer <9.-10 one AIAG Special Process: Welding System Assossment | Version | Issued 3/10 AgerotveIncusty Acton Group 3 SPECIAL PROCESS: WELDING ASSESSMENT Cover Sheet i Section 1-5 4 Section 1: Management Responsibility & Quality Planning Is Section 2: Floor and Material Handling Responsibility 21 Section 3: Equipment “ “ 2 Section 4: Tooling/Fixturing, - 4 Section 5: Process Controls and Confirmation. 24 . ARMac ee°aarCQl-15 Special Process: Welding System Assessment ‘over SI 10, Facility Name: Name of the facility being assessed. One form shall be used for each facility. The facility may have several buildings or physical locations in the same general area. If there isa separate management team or different ‘management system. then these locations shall be considered as separate facilities Address: The street address of the facility being assessed; P.O Box numbers may be given as additional information, Phone Number: The phone number of the facility there is no common phone number for the facility. the phone number of the Operations Manager or Quality Manager shall be used. Fax Number: The fax number of the facility, Number of Welding Employees at this Facility: The number of employees, salaried and houtly. associated with the welding operation at this facility Captive Weld Organization (Y/N): Enter “Y" if this facility welds components for theit own company, Enter “N" if the company does not weld any components for their own company. Commercial Weld Organization (Y/N): Enter “Y" if this facility welds components for companies other than their own company. Enter “N" if this facility does not weld any components for other companies: Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be used to avoid confusion with different numeric formats. Example: May 3 - 4, 2010 Date of Previous Assessment: List the date of the previous CQI-15 Special Process: Welding System Assessment of this facility Type(s) of Welding Processing at this Facility: Place a checkmark to designate all welding process(es) performed at this facility. This information determines the appropriate Process Table that shall be used during the assessment, Processes not listed on the cover sheet ate not part of the Welding System Assessment Current Quality Certification(s): The weld organization shall list their current quality certifications. e-g.. ISO/TS 16949. ISO 9001. Certifications may be from 3rd party sources or customer quality certifications. If customer quality certification is given. then the year of the last assessment by the customer shall also be given.caus AIAG Version 1 issued 3/10 Ausonote ety Beton Glen 16 Date of Re-assessment (if necessary): If “Not Satisfactory” findings were observed from the original assessment, then the weld organization shall address exch item and determine correct action, including root cause analysis and implementation of the corresponding corrective action(s). The date of the re-assessinent shall be given here, and the appropriate Question(s) from Sections 1-5, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the “Number of Not Satistactory Findings” shall be modified as appropriate. Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available, of the principal participants from the weld organization, Auditors/Assessors: List the name(s), Companyties). phone number(s) and email address(es). if available, of the auditor/assessor(s), Number of “Not Satisfactory” Findings: Enter the number of “Not Satisfactory” findings observed during the assessment Number of “Needs Immediate Action” Findings: Enter the number of “Needs Immediate Action” findings observed during the assessment. Number of “Fail” Findings in the Job Audit(s): Enter the number of “Fail from the job audit. indings observed " 3@aar- ‘[Speci CaQl-15 Special Process: Welding System Assessment Version 1 Issa 310 [pet of Wal Prowssaing nthe Faciy [Scsnerged Ar Wolo [cornea WaT anaaee Process Table 8 - Resistance WoT Ressarse socials = Fon tequeney Seon Wel Frcucion Seam Wena = frooees Table C= Laver Welding [ear wan Process Table 0 - Sold Sate Welding [Foren ay Conny lore oRe-zcotsment neces frame [ie [eam [company Fangs [Rampart Far Frnangh nthe Job AvdToD<1 gauss AIAG a Version 1 Issued 3/10, Autti ndsty Instructions for completing Sections 1 — § Sections | - $ contain questions and the requirements and guidance for each question. The Sections are * Scetion 1 ~ Management Responsibility & Quality Planning ‘* Section 2 ~ Floor and Material Handling Responsibility ‘* Section 3 ~ Equipment Facilities/Control Section 4 ~ Tooling/Fixturing © Section 5 ~ Process Controls and Confirmation ss the weld organization compliance to Sections I ~ 5 by comparing the evidence ‘equirements and Guidance ‘The assessor shall ass presented by the weld organization to the requirements listed in the column, ;equirements and Guidance” column, the word “shall” indicates a requirement and the term "such as” indicates that any suggestions given are for | guidance only. i NOTE I In the “Requ [NOTE 2 The “Requirements and Guidance” column will indicate to the assessor when the Process Tables are pertinent to the Questions, When the Process Tables are | pertinent to the Question, the assessor shall assess the weld organization compliance to ified section(s) in the Process Tables. Ifthe question is not applicable to the weld organization, then th ] assessor shall place a checkmark inthe "NiA” Assessment column. It'the observed | evidence is in compliance to the question, the assessor shall note the evidence in the ‘Objective Evidence” column and place a check mark in the “Satisfactory” column. If | the observed evidence is not in compliance to the question, then the assessor shall note | | the non-compliance in the “Objective Evidence” column and place a check mark in the | | Not Satisfactory” column, [NOTE 4: Where nonconforming product is identified in the assessment ofa given | question the assessor shall place a check mark in the “Needs Immediate Action” (NIA) | column. 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I ‘SNRINIXITONTOOL- 7 Uonoes: AE a r — ooperenesion | Koweeaes [yin] savepina easiao suen9 pur sssuinboy onsen Ea Welissossy weyeAs Suipiom ea001d jejoedg 224.CaQli-15 ‘Special Process: Welding System Assessment Ga YWersion tesued 310 cc Taina sd waepen e — =| pf S80 wana eoues] res — | Ionteun put de Guan vote vee res — saioy sees pion oust cote | i 7 prays Bsa00u8 yey saGuEYD SseDa0d us rs ; __ | ssa a retort wis ebisol owe re ono 1) songs buon paar t lnecoats’onny] “tunes. | comune [vn] esonnasamaeo out on — ao Wwowseesey waieks Buipiom is800010 jioedy IGG= 26- cars AIAG Special Process: Welaing System Assessment i Version 1 Issued 3/70, Autemotveindusey Aon Instructions for completing the Job Audit The organization is to complete a minimum of one welding part job audit during each assessment, This should be done preferably on a part identified for one of the customers requiring compliance to this document. More part job audits may be done if time permits, Preferably, safety or critica! parts should be audited. This may not be easily determined with fasteners, especially if the fastener manufacturer does not identify the end customer (auto manufacturer, tier one, etc). Its recommended that the job audit be performed at the end of the welding system assessment * The job audit is not the only or main focus of the WSA. The other five sections on Management Responsibility and Quality Planning, Floor and Material Handling Responsibility. and Equipment Facilities(Control, Tooling Fixturing, and Process Controls and Confirmation are equally if not even more important. The job audit of one part, one weld process, is not sufficient to use as a basis to complete the other sections of the complete WSA. The job audit is a compliance type auditreview of a specific part and its related paperwork and processing, including welding equipment and processing records for that job from the beginning receipt of a part through processing in the welding operation and inspection to packaging, Parts shall be taken from the shipping area at the dock or the end of the welding operation. If an automotive manufacturer's part is not available or identifiable, then parts from other customers requiring compliance with this document shall be used for the assessment. ‘The part checked shall represent a major weld operation such as an individual operation, cell, or assembly line, In subsequent welding system assessments, different parts and welding processes shall be checked. The specific welding processing parameters (applies to 6.1 and 6.13 in the Job Audit) that are required in the job audit shall be added to the job audit form. This can be done by reviewing the customer specification(s), the Control Plan, the FMEA, and the floor work/job order. Each processing step shall be reviewed for proper production records/compliance/inspection, These steps can be compared to those in the Welding System Assessment for the actual job/welding process being reviewed for compliance. The welding records for the actual time frame/shift ete. that the job was processed shall also be checked. The actual welding equipment and instrumentation certification shall be verified as being in compliance to the appropriate equipment requirements in the equipment section, -aaeaea “aeer ac”cal-15 Version 1 Special Process: Welding System Ass TEST Ga utrmote ey Bo upny qor- 9 uonsagAutomotive ngvey Acton Grou Special Process: Welding System Assessment Version 1 Issued 3/10 CaQl-15 Jo sbueus pojuaunana © fesse (oon enoetao) ‘voumueg ony onewauinoog eousi0e 10 0910 (ug) aor s vonsen) uUpny gor - 9 uonoas. -28-CaQl-15 Special Process: Welding System Assessment Version 1 aswed 390 Ga CES 11 Weusanba, ysee eau anu weg a4 4 Boununep siuseenbas Bou 10 aUo ane feu Ho oes ae Tsova03 amped) woupue9 ery uv (andes 29.AIAG 2» ‘Special Process: Welding System Assessment Version 1 Issued 310 CaQl-15 é -.~-JBUBL____ _30_3886. Ltt | 24053 59130) esses 0820) | sepeyaunoag ume woweanboa ‘ruonsen@ vm ‘voor eae ew 0 everen9 pons s vonsono pny dor 9 uons0g -30-AIAG 2 caus APPENDIX A — PROCESS TABLES Process Table A: Arc Stud Fastener Welding. Flux-Cored Are Welding, Gas Metal Are Welding Submerged Are Welding. Shielded Metal Are Welding. Plasma Arc Welding. Gas Tungsten Are Weld and Gas Metal Are Braze Welding, o Process Table B: Resistance Spot Welding. Projection Welding, Resistance Seam Welding, High- Frequency Seam Welding, Induction Seam Welding. Mash Seam Welding, and Flash Welding Process Table C: Nd YAG, CO2, DIODE, and Wire Fed. 36 Process Table D: Inertia Friction Welding. 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Supiem | Burpiom Buren une] Surpion sisou |uina useig sdaig ssororaitvobore: wwonsua | uontug 1s ssepongihioBo1e9 /exua wong) eneuy ‘Kiess900u usw paiuawnoop pue pamarre) oq pinous simpe204d 184) Sieaypur | ;Patioaves pur payusunoop oq eys Yawn ayqeies fequasse ue tele (de 1. aeoypuy moyeg sausea| ‘quowexnbas ~pne ou ‘upne got au Buiuoped ueum “219 sajouanbo1 1ye016 Gunse} uonoodsur "Ge nisowonsber inn siuowoxmnbos ayoode saworsno 0} Sessoooig Bupiom oieis pos “CHTEVI SSIOOWd Jo¥3N9 94} 0} BujI0}UO s4 Burplom Ays9H iEYs -47--48- Cal-15 ‘Special Process: Welding System Assessment Version 1 Issued 370 AIAG 2» Autoratve indy Acton Group 7Raac aeAIAG cals Version 1 Issued 30 GLOSSARY See also AWS A: ‘elding terms and definitions AIAG ~ Automotive Industry Action Group AWS American Weldi Society ANSI American National Standard Institute Capability ~The total range of inherent variation in a stable process. Control Plans ~ Written descriptions of the system for controlling processes for production of parts or bulk materials, Control Plans ate written by organizations to address the important characteristics and engineering requirements of the product. Each part must have a Control Plan, but in many cases, “family” Control Plans can apply to a number of parts produced using a common process. Critical Spare Parts List ~ A list of service parts critical for the operation of equipment. Extended delay in obtaining spare parts would result in unacceptable delays in the welding operation. Cross-Functional Team ~ A team of employees that represent the different functions within an organization. The team will typically consist of an operator, line supervision, process engineer, metallurgist, and quality personnel Customer ~The recipient of the organization's or supplier's product or service Customer Requirements ~ This term refers to the requirements or specifications from the original equipment manufacturer (typically the automobile company). These may be identified in the contract or purchase order, in engineering standards, part specifications, ete Inter-Lock ~ A method of preventing missed steps within the operations by putting controls on how an ‘operation can be performed in order to force the correct completion of the operation. Nonconforming Product ~ Product that does not conform to the customer requirements. Process Tables ~ Tables in the WSA that list the required process controls for the welding processes covered, These tables contain minimum requirements. Reprocessing ~ Any process that is performed on nonconforming product so that it will meet the specified requirements, Responsibility Matrix ~ A responsibility matrix defines the designated personnel for all key functions. This matrix includes the primary and secondary designees of variation within operating window: able to withstand Robust — A stable predict its environment, not prone to failure. ve outcome regardless SAE International ~ Society of Automotive Engineers Intemational Shop Traveler ~ A document usually created in the receiving department for each batch or lot of parts received, The document detines the process routing of the parts. Special Characteristics — are product characteristics or manufacturing process parameters which can fect safety or compliance with regulations, fit, function, performance or subsequent processing of product, Refer to customer-specifie requirements WSA - Welding Syst » Assessment 49.canis AIAG a Version t Issued 3/10, Ausorotve Work Instru inspection, welding operation. process parameter tolerances, ec. The term “work instructions” synonymous with the term “job instructions.” Aeton G ms ~ Instructions that describe work conducted in one function in a company, e.g. setup, JAAAaAS”AIAG a oe "MAINTENANCE REQUEST FORM Name of Submitter: Date: __ — Company: Company Address: Phone: Fax: CO uae iecus Page Number of Change: Document Currently Reads: Recommended Changes/Should Read: Reason for Change (Use additional sheets if necessary): _ Signature of Submitter: DISPOSITION (AIAG USE ONLY) Manager's Recommendation: ger Final Disposition: Comments: MST ee ‘Southfield, Mi 48033 Coenen needa ‘Automotive Industry Action Group + 26200 Lahser Road * Suite 200 Telephone: (248) 358-3570 + Fax: (248) 358-3253, Web: www.aiag.org