Cqi 12

CQI-12v2
Special Process: Coating System Assessment
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© 2012 Automotive Industry Action Group
© 2012 Automotive Industry Action Group

ISBN#: 978-1-60534-245-0-90000
CQI-12v2
1
Dated: 2/2012
CQI-12
Version 2 Issued 2/2012
Special Process: Coating System Assessment 2nd Edition
Facility Name: Jackson Tumble Finish

Address: 1801 Mitchell Street, Jackson, MI. 49201
Phone Number: (517) 787-0368 Type(s) of Coating Processes at this Facility:

Fax Number: (517) 787-8752 Process Table A
Pretreatment, Aqueous Yes
Number of Coating Employees at this Facility: Process Table B
40 Hourly/5 Salary Not Applicable Do Not Mechanically Pretreat
Captive Coater (Y/N): No Process Table C
Commercial Coater (Y/N): Yes Conversion Coating Yes
Process Table D
Date of Assessment: 8/13/2018 Not Applicable Do Not Powder Coat
Process Table E
Date of Previous Assessment: 8/28/2017 Not Applicable Do Not Spray
Process Table F
Not Applicable Do Not Electrocoat
Process Table G
Not Applicable Do Not Dip Spin
Process Table H
Not Applicable Do Not Autodeposit
Process Table I
Not Applicable Do Not Cure
Process Table J
Not Applicable Do Not Anodize
Process Table K
Equipment Yes
Process Table L
Part Inspection & Testing Yes
Current Quality Certification(s): ISO 9001: 2015, IATF 16949 Compliant through customer/3rd party assessment.
Date of Re-assessment (if necessary):
Personnel Contacted:
Name: Title: Phone: Email:
Denise Losey President (517) 787-0368 denise@jacksontumble.com
Daniel Guerrero Plant Supervisor (517) 787-0368 daniel.guerrero@jacksontumble.com
Michelle Morrison QA Manager/Mgnt. Rep. (517) 787-0368 michelle@jacksontumble.com
Sean Hagerman Sales Representative (517) 787-0368 sean@jacksontumble.com
Auditors/Assessors:
Name: Company: Phone: Email:
Denise Losey / Lead Assessor Jackson Tumble Finish 517-990-8894 denise@jacksontumble.com
Michelle Morrison / Lead Assessor Jackson Tumble Finish 517-990-8893 michelle@jacksontumble.com
Number of "Not Satisfactory" Findings:

Nothing Unsatisfactory, the relevant areas of the Base Processes remain the same, Via Internal Assessments/ 2/year
Number of "Needs Immediate Action" Findings:

Same as Above, however various customer recommendations were addressed and changed as/if required.
Number of "Fail" Findings in the Job Audit(s):

No Failures observed / All process considerations reviewed for accuracy and process output per Customer Specification.
Number of Process Table Items not meeting Minimum Requirements:

None
© 2012 AIAG (Automotive Industry Action Group)

CQI-12
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Not Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action
Section 1 - Management Responsibility and Quality Planning
1. Daniel Guerrero (Production

Manager)
To ensure readily available expertise, there shall be a 2. Production Manager is a Full-Time
dedicated and qualified coating person on the site. employee.
This individual shall be a full-time employee and the 3. Production Manager is a direct report
position shall be reflected in the organization chart. A to the President. 4. Full
Is there a dedicated and
job description shall exist identifying the qualifications Job Description resides with the
1.1 qualified coating person on-
for the position including chemical and coating President. X
site?
knowledge. The qualifications shall include a 5. Production Manager maintains 12+
minimum of 5 years experience in coating operation or years experience of coating operations.
a combination of a minimum of 5 years of formal Individual training plans and matrix for
chemical education and coating experience. all employees. All Training
Qualifications reside in the Employee
Recofd File, CD-033.
The coater shall incorporate a documented advanced

1. APQP Activities completed at time of
quality planning procedure. A feasibility study shall be
Quote. (Doc #CD-024)
performed and internally approved for each new part
2. Feasibility study is
or process. Similar parts can be grouped into part
completed at the time of Quote. (Doc
families for this effort as defined by the coater. After
Does the coater perform #CD-024) 3.
1.2
advanced quality planning?
the part approval process is approved by the
Customer is contacted by the Quality X
customer, no process changes are allowed unless
Manager when clarification is needed
approved by the customer. The coater shall contact
for process changes.
the customer when clarification of process changes is
4. Process changes are
required. This clarification of process changes shall
documented by updating the PPAP.
be documented.

CQI-12
Assessment

1. Process FMEA up-to-date reflecting

The coater shall incorporate the use of a documented
current processing. PFMEA structured
Failure Mode and Effects Analysis (FMEA) procedure
to current Revision AIAG documents.
and ensure the FMEAs are updated to reflect current
2. Process
part quality status. The FMEA shall be written for
FMEAs are written to reflect process
each part or part family or they may be process-
families. 3.
Are the coater's FMEA's up to specific and written for each process. In any case,
Process FMEAs include all steps from
1.3 date and reflecting current they shall address all process steps from part receipt
receiving customer product to shipping X
processing? to part shipment and all key coating process
of product. 4.
parameters as defined by the coater. A cross-
Process FMEA team includes,
functional team shall be used in the development of
President, Quality and Production.
the FMEA. All special characteristics, as defined by
5. Special and critical characteristics
the coater and its customers, shall be identified,
are addressed at time of Quote (Doc
defined, and addressed in the FMEA.
#CD-024)
The coater shall incorporate the use of a documented

Control Plan procedure and ensure the Control Plans
are updated to reflect current controls. The Control
Plans shall be written for each part or part family or 1. Control Plans are structured to
they may be process-specific and written for each current AIAG documents.
process. In any case, they shall address all process 2. Control Plans are written to reflect
steps from part receipt to part shipment and identify all process families. 3.
equipment used and all key coating process Control Plans include all steps from
parameters as defined by the coater. A cross- receiving customer product to shipping
Are finish process Control
functional team, including a production operator, shall product. 4. The
1.4 Plans up to date and
be used in the development of Control Plans, which team consists of the President, Quality X
reflecting current processing?
shall be consistent with all associated documentation and Production. 5. Control Plans are
such as work instructions, shop travelers, and FMEAs. consistent with work instructions.
All special characteristics, as defined by the coater 6. Special and critical
and its customers, shall be identified, defined, and charracteristics are identified at time of
addressed in the Control Plans. Sample sizes and quote. 7. Sample sizes are
frequencies for evaluation of process and product determined at start of PPAP.
characteristics shall also be addressed consistent with
the minimum requirements listed in the Process
Tables.

CQI-12
Assessment

1. Standards and requirements are

To ensure all customer requirements are both reviewed at quote time through use of
understood and satisfied, the coater shall have all Doc#CD-024. CD-024 additionally is
related coating and customer referenced standards used to verify JTF has the current
and specifications available for use and a method to revision level.
ensure that they are current. Such standards and 2. Review of the most current
specifications include, but are not limited to, those standards and requirements are
relevant documents published by SAE, AIAG, ASTM, completed/verified at quote time.
General Motors, Ford, and Chrysler. The coater shall 3. Changes and updates due to
Are all coating related and have a process to ensure the timely review, standards and requirements are
referenced specifications distribution, and implementation of all customer and completed on the same day that the new
current and available? For industry engineering standards and specifications and standards/requirements are reviewed.
1.5
example: SAE, AIAG, ASTM, changes based on customer-required schedule. This 4. X
General Motors, Ford, and process shall be executed as soon as possible and Same day - not exceeding two weeks.
Chrysler. shall not exceed two weeks. The coater shall 5.
document this process of review and implementation, Review and implementation is
and it shall address how customer and industry documented through our Change
documents are obtained, how they are maintained Management Procedure.
within the coater, how the current status is 6. Customer and Industry documents
established, and how the relevant information is are obtained at quote time and are
cascaded to the shop floor within the two-week period. mainted through the Document Control
The coater shall identify who is responsible for Procedure. 7.
performing these tasks. Roles and responsiblity is defined for
each Procedure in the QMS.
The coater shall have written process specifications

for all active processes and identify all steps of the 1. All written processes are contained
process including relevant operating parameters. within the Work Instructions (CD-019).
Examples of operating parameters include process 2.
temperatures, cycle times, load rates, rectifier All operating parameters are included in
Is there a written process
settings, etc. Such parameters shall not only be the work instructions.
1.6 specification for all active
defined, they shall have operating tolerances as 3. All operating tolerances are X
processes?
defined by the coater in order to maintain process included in the work instructions.
control. All active processes should have a written 4. All processes that are
process specification. These process specifications offered at JTF havea formal written work
may take the form of work instructions, job card, instruction.
computer-based recipes, or other similar documents.

CQI-12
Assessment

1. Process capability studies are

completed through sample runs. 2.
To demonstrate each process is capable of yielding
Major rebuild or improvements to our
acceptable product, the coater shall perform product
processing lines are proprietary
capability studies for the initial validation of each
information.
process, after relocation of any process equipment,
3. Initial process capability studies are
and after a major rebuild of any equipment. The
completed through sample runs for all
coater shall define what constitutes a major rebuild.
proceses.
Initial product capability studies shall be conducted for
4. All Capability Studies include
all coating processes per line as defined in scope of
Has a valid product capability coating weight review/validation.
work and in accordance with customer requirements.
1.7 study been performed initially
Capability study techniques shall be appropriate for
5. Customer requirements X
and after process change? are validated at PPAP and/or initial
the coating product characteristics, e.g., coating
sample run.
thickness, corrosion resistance, etc.. Any specific
6. JTF follows ASTM standards at
customer requirements shall be met. In the absence
the absence of customer requirements.
of customer requirements, the coater shall establish
7. In case capability
acceptable ranges for measures of capability. An
falls outside the requirements, action
action plan shall exist to address the steps to be
plans are recorded and handled via the
followed in case capability indices fall outside
PPAP - process changes are made with
customer requirements or established ranges.
revalidation and PPAP is updated to the
next Rev. level.
The analysis of products and processes over time can 1. JTF collects and analyzes data from
yield vital information for defect prevention efforts. coating weights, bath additions, and
The coater shall have a system to collect, analyze, frequency of additions (CD-065 and CD-
Does the coater collect and and react to product or process data over time. 123). 2.
analyze data over time, and Methods of analysis shall include ongoing trend or Data is collect and analyzed twice daily
1.8 react to this data? Are historical data analysis of special product or process via coating panels and recorded in our X
records available? parameters. The coater shall determine which historical data collection. 3. This
parameters to include in such analysis. All process data is stored electronically and backed
control and testing records must be retained for a up for the life of JTF and includes
minimum of one calendar year after the year in which coating weights, bath additions and
they were created. frequency of additions.

CQI-12
Assessment

1. Internal assessments are completed

annually using AIAG CSA.
Are internal assessments
The coater shall conduct internal assessments on an 2. Concerns
being completed on an annual
1.9
basis, at a minimum,
annual basis, at a minimum, using the AIAG CSA. that are identified during the annual X
Concerns shall be addressed in a timely manner. review are handled through internal 8D's
incorporating AIAG CSA?
and the Corrective/Preventative Action
process .
1. Reprocessing is controlled by QA
Department. (CD-136, CD-018) 2.
The quality management system shall include a
Reprocessing is contained with the
documented process for reprocessing that shall
work instructions (CD-019) and signed
include authorization from a designated individual.
off by either the Production Manager or
The reprocessing procedure shall describe product
Quality Manager. 3. CD-
characteristics for which reprocessing is allowed as
019 work instructions states the rework
Is there a system in place to well as those characteristics for which reprocessing is
and the parameters in which to process
1.10 authorize reprocessing and is not permissible. All reprocessing activity shall require
the rework. 4. All X
it documented? a new processing control sheet issued by qualified
reprocessing is provided a new CD-019
technical personnel denoting the necessary coating
issued by Production and Quality.
modifications. Records shall clearly indicate when and
5.
how any material has been reprocessed. The Quality
Rework processing is clearly stated in
Manager or a designee shall authorize the release of
the work instructions. 6.
reprocessed product.
Quality Manager signs off on all
reprocessed material.
The quality management system shall include a

Does the Quality Department 1. JTF has a Matrial Review Report
process for documenting, reviewing, and addressing
review, address, and system CD-133 MRR.
1.11
document customer and
customer concerns and any other concerns internal to
2. 5-Why and 8-Ds are X
the coater. A disciplined problem solving approach
internal concerns? used.
shall be used.

CQI-12
Assessment

1. Continual Improvement Procedure

8.5.
The coater shall define a process for continual
2. Continual Improvement
improvement for each coating process identified in the
Is there a continual Procedure 8.5, Section 8.5.1.1.
scope of the CSA. The process shall be designed to
improvement plan applicable 3. and 4. Action Item work
1.12
to each process defined in the
bring about continual improvement in quality and
sheet is used for prioritization and X
productivity. Identified actions shall be prioritized and
scope of the assessment? timing. 5. Continuous
shall include timing (estimated completion dates). The
Improvement verified with analyzing
coater shall show evidence of program effectiveness.
data and equipment upgrades and new
equipment being purchased.
Does the Quality Manager or

The Quality Manager or designee is responsible for 1. Responsibility belongs to the QA
designee authorize the
1.13
disposition of material from
authorizing and documenting appropriate personnel to Manager and documented through the X
disposition quarantine material. MRR system.
quarantine status?
There shall be procedures or work instructions 1. Work Instructions (CD-019) available

available to coating personnel covering the coating on the floor at each process.
process. These procedures or work instructions shall 2. Work
Are there procedures or work
include methods of addressing potential emergencies instructions include start-up, operating,
instructions available to
1.14
coating personnel that define
(such as power failure), equipment start-up, and shut down. Reaction plans for non- X
equipment shut-down, product segregation (See 2.8), conforming product covered in work
the coating process?
product inspection, and general operating procedures. instructions. 3.
These procedures or work instructions shall be Work Instructions are available at each
accessible to shop floor personnel. station.
1. Training Procedure 6.2

The coater shall provide employee training for all 2.
coating operations. All employees, including backup Training Procedure 6.2, Section 6.2.2.3
and temporary employees, shall be trained.
Documented evidence shall be maintained showing 3. and 4. Employee
Is management providing
1.15
employee training for coating?
the employees trained and the evidence shall include Records, CD-033 X
an assessment of the effectiveness of the training. 5. Per
Management shall define the qualification Training Procedure 6.2
requirements for each function, and ongoing or follow- 6. Training
up training shall also be addressed. Procedure 6.2, Sections 6.2.2a thru
6.2.2.e

CQI-12
Assessment

The coater shall maintain a responsibility matrix 1. Responsibility/Training Matrix is

Is there a responsibility matrix identifying all key management and supervisory maintained and all training catagories
to ensure that all key functions and the qualified personnel who may and cross-training is documented. CD-
1.16 management and supervisory perform such functions. It shall identify both primary 033. X
functions are performed by and secondary (backup) personnel for the key 2. Primary and Secondary are
qualified personnel? functions (as defined by the coater). This matrix shall identified for Key Functions
be readily available to management at all times. 3. Matrix is on the shared drive.
1. Preventive activities are performed

and documented. CD-041 & 42.
The coater shall have a documented preventive
2. Maintenance Work Orders are used
maintenance program for key process equipment (as
to tracked completion and effectiveness.
identified by the coater). The program shall be a
3. All
closed-loop process that tracks maintenance efforts
employees can fill out the maintenance
Is there a preventive from request to completion to assessment of
work orders. 4.
maintenance program? Is effectiveness. Equipment operators shall have the
Maintenance Manager ensures final
maintenance data being opportunity to report problems, and problems shall
1.17
utilized to form a predictive also be handled in a closed-loop manner. Company
closure of work orders and reports out at X
weekly management meetings.
maintenance program? data, e.g., downtime, quality rejects, first time-through
5.
capability, recurring maintenance work orders, and
Improvements are identified and action
operator-reported problems, shall be used to improve
items given at weekly management
the preventive maintenance program. Maintenance
meeting. 6.
data shall be collected and analyzed as part of a
Maintenance data is collected/reviewed
predictive maintenance program.
in weekly management meetings and
management reviews.
Has the coater developed a

1. CD-042 / 30 Day Key
critical spare parts list, and The coater shall develop and maintain a critical spare
Equipment/Replacement Parts List
1.18 are the parts available to parts list and shall ensure the availability of such parts
2. Replacement Parts are X
minimize production to minimize production disruptions.
available immediately.
disruptions?

CQI-12
Assessment

Section 2 - Floor and Material Handling Responsibility

Does the facility ensure that 1. JTF Work Ticket generated to
Documented processes and evidence of compliance
the data entered in the replicate part information received with
shall exist, e.g., shop travelers, work orders, etc. The
2.1 receiving system matches the
facility shall have a detailed process in place to
customer order. Travelor Ticket CD-019. X
information on the customer's
resolve receiving discrepancies.
shipping documents? 2. Material Review Report CD-133
Procedures for part and container identification help to 1. JTf work tciket, CD-019, maintained
avoid incorrect processing or mixing of lots. with order through the process. JTF
Appropriate location and staging within the facility also runs bin for bin to maintain the lot
help to ensure that orders are not shipped until all integrity as received from the customer.
Is product clearly identified
required operations are performed. Customer product 2.
2.2 and staged throughout the
shall be clearly identified and staged throughout the Finished Product and Unfinished X
coating process?
coating process. Non-coated, in-process, and finished Product are kept segrated in the
product shall be properly segregated and identified. All Shipping Department.
material shall be staged in a dedicated and clearly 3. All material is kept segrated in the
defined area. shipping department.
Out-going lot(s) shall be traceable to the incoming

Is lot traceability and integrity lot(s). The discipline of precisely identifying lots and
1. Lot control captured on Work Ticket /
2.3 maintained throughout all linking all pertinent information to them enhances the
Shop Traveler. CD-019. X
processes? ability to do root cause analysis and continual
improvement.
The control of suspect or non-conforming product is 1. All stages, from receiving,

necessary to prevent inadvertent shipment or processing, and shipping include
contamination of other lots. Procedures shall be nonconforming Procedures.
Are procedures adequate to
adequate to prevent movement of non-conforming 2. Procedures secure
prevent movement of non-
2.4
conforming product into the
product into the production system. Procedures shall nonconforming product to the X
exist addressing proper disposition, product Containment Area, accompanied by a
production system?
identification and tracking of material flow in and out of Material Review Report, CD-133.
hold area. Non-conforming hold area shall be clearly 3. Non-conforming hold
designated to maintain segregation of such material. area is clearly mark as Quality Hold.

CQI-12
Assessment

1. Processing container inspections are

Is there a system to identify perfromed for trap points and reacted to
trap points in the entire The coater shall have documented procedures to if detected.JTF utilizes a QUALITY
process to reduce risk of identify and monitor trap points for each ALERT- Dropped Part Policy. Dropped
2.5
mixed parts (inappropriate, process/equipment. Monitoring of potential trap points parts are not put back in population. X
unfinished or improperly shall occur for every part changeover. Scrapped, Customer Notified, or both.
coated parts)? 2. Trap points
are inspected at every part changeover.
1. Contamination of containers is
Containers handling customer product shall be free of reviewed at receiving, processing, and
inappropriate material. After emptying and before re- shipping. Reaction plans from MRR
using containers, containers shall be inspected to System, CD-133/Nonconforming.
Are containers free of ensure that all parts and inappropriate material have 2. Containers are line
2.6
inappropriate material? been removed. The source of inappropriate material inspected for the removal of all parts and X
shall be identified and addressed. This is to ensure inappropriate material.
that no nonconforming coated parts or inappropriate 3. MRR System, CD-133/Non-
material contaminate the finished lot. conforming addresses inappropriate
material.
Loading parameters shall be specified, documented

and controlled. Examples include parts per rack and 1. Loading parameters established by
Is part loading specified,
2.7
documented and controlled?
load size. weight and product handling instructions X
when provided.
Refer to Process Tables for frequency of checks.

CQI-12
Assessment

1. JTF has work instrustions for matrial

handling, containment action, and
product segregation. Training includes
Unplanned or emergency downtime greatly raises the
work instructions which include power
risk of improper processing. Operators shall be trained
failure. Included in Employee Records
in material handling, containment action, and product
Are operators trained in File, CD-033. 2. Training is
segregation in the event of an equipment emergency
material handling, documented per CD-033.
including power failure. Training shall be documented.
containment action and 3. Work
Work instructions specifically addressing potential
2.8 product segregation in the
types of equipment emergencies and failures shall be
Instructions CD-019 identify potential X
event of an equipment types of failure and are kept on the line
accessible to and understood by equipment
emergency including power for operators to reference when or if
operators. These instructions shall address
failure? needed. 4. Work
containment/reaction plans related to all elements of
Instructions address containment and
the process. Evidence shall exist showing disposition
reaction plans. 5. The
and traceability of affected product.
MRR CD-133 is evidence showing the
disposition/tracability of non-conforming
product.
1. Adequate warehousing available for

Is the handling, storage and The coater's loading/unloading systems, in-process bin storage and staging.
2.9 packaging adequate to handling and shipping process shall be assessed for Dampening/Deflecting Boards are used X
preserve product quality? risk of part damage or other quality concerns. when dumping product, at minimal
heights.12-18"

CQI-12
Assessment

1. Plant Cleanliness maintained for

working conditions to meet product
quality requirements.
Plant cleanliness, housekeeping, environmental, and
2. Safety and Quality conducts a
working conditions shall be conducive to controlling
Are plant cleanliness, monthly walk around to ensure plant
and improving quality. The coater should evaluate
housekeeping, environmental cleanliness and working standards are
such conditions and their effect on quality. A
2.10 and working conditions
housekeeping policy shall be clearly defined and
being met. Safety walks around X
conducive to control and unannounced on a daily basis. 3.
executed. The facility shall be reviewed for the
improved quality? Housekeeping policy is posted in the
following items: loose parts on floor; spillage around
employee break room.
tanks; overall plant lighting; fumes etc.
4. Safety and Quality conducts the
facility walk through on a monthly basis.
1. Testing completed prior to shift

starting and process checks conducted
Process control parameters shall be monitored per
daily by operators to maintain and verify
Are process control frequencies specified in Process Tables. Computer
process parameters. CD 123.1,2,3,4.
parameters monitored per monitoring equipment with alarms and alarm logs
2.11
frequencies specified in satisfy the verification requirement. A designated floor
Maintained and kept electronically. 2. X
Line Leaders as well as Production
Process Tables? person shall verify the process parameters, e.g., by
Manager verifies process parameters -
initialing a strip chart or data log.
Production Manager maintains the data
log.
There are documented reaction plans to both out of

Are out of control/specification 1. Reaction plans are followed and
control and out of tolerance process parameters.
2.12 parameters reviewed and
There is documented evidence that reaction plans are
deferred from/to Control Plan, CD-076.3 X
reacted to? Control Plan.
followed.
Are In-Process / Final Test In-Process / Final Test Frequencies shall be 1. In-Process and Final Inspection
2.13 Frequencies performed as performed as specified in Process Tables. Refer to performed as specified in Process X
specified in Process Tables? Process Tables. Tables. (Table C).

CQI-12
Assessment

1. All MTE calibrated, and documented

Test equipment shall be verified/calibrated per
in the cal. System. Frequencies are
applicable customer specific standard or per an
established in meet the requirements of
applicable consensus standard, e.g., ASTM, SAE,
Is product test equipment Table K. All cal. Activities traceable to
2.14
verified?
ISO, NIST, etc. Verification/calibration results shall be
National Standards. X
internally reviewed, approved and documented.
2. Verification is reviewed by
Management at the weekly Management
Refer to Process Tables for frequency of checks.
meetings.

CQI-12
Assessment

Lighting in the inspection area must be sufficient to

allow the evaluation of all part surfaces. The lighting 1. Lighting throughout facility including
Is lighting of inspection area
2.15
adequate?
shall be arranged to preclude spot lighting, glare or inspection areas is adequate for part X
shadows. There can be no moving or distracting surface inspection.
reflections on the surfaces to be evaluated.
Identify operating parameters including:

- number of rinse tanks between process stages,
- tank type (single rinse, counter flowing, stationary
rinse, spray rinse) 1. Rinse water tanks between process
Are the water rinse Control
- flow rate, tanks are adequate for meeting
2.16 Plans up to date and reflect
- water requirements (city or deionized water, reverse processing requirements. These are X
best case practices?
osmosis), Free Flowing/Self Cleaning rinses.
- filtration (if applicable)
- control methods
- temperature (if applicable)
Aware of water quality and it's impact on each specific 1. Water quality adequate for
2.17 Is the water quality adequate? process. Purified water is used where necessary, or processing. JTF uses City Water, and in X
where specified. some processes, DI Water. .

CQI-12
Section 3 - Job Audit - Finished Product Review
Job Identity: CALCIUM MODIFIED FINE PHOSPHATE AND NITRITE BASED DRY RP.
Customer: ELM PLATING & HEAT TREATING
Shop Order Number: WORK ORDER #156005
Part Number: W709980S442
Part Description: BOLT / FASTENER 5 CONTAINERS
Coating Requirements: CALCIUM MODIFIED FINE PHOSPHATE & RP. Per TENNECO PS-119.5
Job (Shop) Order or

Related Customer or Internal Actual Condition Pass /
Question # Job Audit Question Reference Documentation
CSA Question # Requirement (Objective Evidence) Fail / N/A
Requirement
1.1
PRRC CD-024, P Flow
Is contract review and advanced quality 1.2
Calcium Modified Fine CD-076.1, PFMEA CD-
3.1 planning, FMEA, Control Plans, etc., 1.3 WORK ORDER #156005 Pass
phosphate and Nitrite RP. 076.2, C Plan CD-
performed by qualified individuals? 1.4
076.3,WI 3.1-3.20.
1.6
Tenneco Specification PS- Copy of Spec. in Spec File, Tenneco PS 119.5

Does the coater have the proper 119.5 Current Revision Revision G, dated 03-
3.2 1.5
customer specifications for the part? 17-2009
Pass
Yes, Work Ticket CD-019 Signarture Sign-Offs by: Rec., CD-019 W/signatures
Is a shop traveler created to meet 1.6 Processing, and Shipping.. filed at time of shipping.
3.3
customer requirements? 2.1
Pass
Is material identification (part numbers, lot Yes Job Traveler remains with Metal Sleeves on each
2.2 product through the intire process container to
numbers, contract numbers, etc.)
3.4 2.3 process. Attached to retain Traveler, CD-019
maintained throughout the coating
2.4 processing container.
process? Pass
Yes, Work Ticket CD-019 Upon Insp. Of 20 random Receiving Inspection on
samples/container, Rec. Insp. Traveler, CD-019
Is there documented evidence of
3.5 2.1 Signs Traveler CD-019
Receiving Inspection?
Pass

CQI-12
Job (Shop) Order or

Requirement
1.6 Any Customer specific On CD-019, filed.
Are the Loading / Racking requirements reqmts will be on CD-019,
3.6 2.7
identified? Traveler.
2.9 Yes, Per Rack/Barrel Pass
Yes, Internal to achieve Three specific (Critical
Is the proper procedure or process 1.5 External Specification to
specification used? Refer to Process 1.6 requirements. Process Output) para-
3.7 Tables for specific parameters. List 2.1 meters are performed
parameters that were verified in this audit 2.11 daily and recorded ele-
in the spaces provided below. 2.13 tronically. Stored for 3
years + YTD
Pass
Phosphate Temperature
Per Process: 140-165 Deg. F Recorded Elect. Actual: 158 Deg. F

Pass
Time in Phosphate
Per Process: 8-15 Minutes Recorded Elect. Actual: 12 Minutes Pass

Coating Wt. in g/m2
Per PS-119.5 100-400 Mg/Sq F Recorded Elect. Actual: 304 Mg/Sq Ft.
Pass

CQI-12
Job (Shop) Order or

Requirement
1.5 Each part may have one or more requirements determined by the coating specification.
What are the product inspection
3.8 2.13 Parts must meet each requirement. List each requirement below and validate.
requirements?
2.14 (Listed below are some examples)
Actually Coating Weight
3.8.1 Requirement: Coating Thickness
Pass
Test Method: ASTM B 767 / Rev-2006
Test frequency or quantity: One Panel Per Phos.Bath/Daily Record on Elect. Data Sheet 304 Mg/Sq Ft.
Selection of samples: ASTM Panel
Specification: Per Spec:100-400 Mg/Sq Ft. Record on CD123/Initial 304 Mg/Sq Ft.
Requirement: Corrosion Resistance (if
3.8.2
applicable) No Salt Spray Required N/A
Test Method(s):
Test frequency or quantity:
Selection of samples:
Specification:
Requirement: Hydrogen Embrittlement

3.8.3
Relief (if applicable)
No Hyd. Emb. Required N/A
Test Method:

CQI-12
Job (Shop) Order or

Requirement
Specification:
3.8.4 Requirement: Adhesion N/A
Test Method(s):
Specification:
3.8.5 Requirement: Cure No Cure Required N/A
Test Method:
Specification:
Requirement: Torque Tension
3.8.6
(if applicable) No TT Required N/A
Test Method:

CQI-12
Job (Shop) Order or

Requirement

CQI-12
Job (Shop) Order or

Requirement
Specification:
3.8.7 Requirement: Appearance (Decorative) No Appearance Reqmt. N/A
Test Method:
Specification:
Requirement: Dimensional
3.8.8
(if applicable) SEM Test (Crystal Size-Max) At 1000 Magififcation SEMs Max=25 Microns Pass
Test Method: Actual=1-3 Microns
Test frequency or quantity: RTI- A2LA Laboratory
Specification:
Requirement: Color and Gloss
3.8.9
(Decorative) No Decorative Reqmt. N/A
Test Method:
Specification:

CQI-12
Job (Shop) Order or

Requirement
3.8.10 Requirement: Customer Specific TENNECO SPEC. N/A
Test Method(s):
Specification:
Operator or Inspector Responsibilities
1.4
1.6
Were appropriate process steps signed
3.9 2.2
off?
2.3
2.11
Operator Sign-Off CD019 Operator Sign-Off CD019 CD-019 Stored 3 Years Pass
Were all inspection steps, as documented 1.2

3.10
in the Control Plan performed? 1.4
Receiving Inspection, Process Insp., Shipping Insp.Sign-Off On CD019 Pass

CQI-12
Job (Shop) Order or

Requirement
Were steps/operations performed that 1.2

3.11 were not documented in the Control 1.4
Plan? 1.6
N/A N/A No N/A
1.2
1.4
If additional steps were performed, were
3.12 1.6
they authorized?
1.10
1.16 Would Be N/A N/A None Performed N/A
Does the governing specification allow 1.5

3.13
reprocessing or rework? 1.10
N/A N/A Does Not Specify N/A
If the order was certified, did the
2.11
3.14 certification accurately reflect the process
2.13
performed? Per Customer Specific Spec. Certification Sheet Cert.: Tennecp PS-119.5 Pass
Was the certification signed by an
3.15 1.16
authorized individual? Per QA Mgmt. M. Morrison QA Mgr. Electronic Signature Pass
Are the parts and containers free of

3.16 2.6
inappropriate objects or contamination?
Reviewed Prior to PKG Packaging Operator Review Per Requirements Pass

CQI-12
Job (Shop) Order or

Requirement
Packaging Requirements
2.6
3.17 Are packaging requirements identified? 2.7
2.9 At APQP Activities If Specific-on CD-019 Bulk In / Bulk Out Pass
Are parts packaged to minimize mixed 2.6
3.18 parts (for example, parts packed over 2.7
height of container)? 2.9 Process Container to ContainerHeadspace Reqiuired InternallyHeadspace Provided Pass
Shipping Requirements
2.3 Per full Part # plus Revision Per full Part # plus Revision All Cust. Tags remain in Pass
3.19 Were the parts properly identified? Original Container
2.9
2.3
3.20 Were the containers properly labeled?
2.9 Per full Part # plus Revision Per full Part # plus Revision See 3.19 Pass

CQI-12
PROCESS TABLE A - Pretreatment (Aqueous)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Related
Item # CSA Category/Process Steps Type of Control Monitoring Frequency Observation/Comments
Question #
Minimum
Actual Condition Minimum Requirement Actual Condition (Pass / Fail / N/A)
Requirement
1.0 AQUEOUS CLEANING PROCESS (Alkaline or Acid)
There shall be an incoming part assessment procedure

A1.1 1.4
with criteria.
Per Control Plan Per Control Plan Once per lot and per part change Pass
Once per lot
Automatic Line: Confirm set-up at the start

of production and every process change.
1.4 Manually verify every 3 months or after
Continuously monitored
1.6 programming change or equipment
A1.2
2.11
Time Automatic/Manual Manual
maintenance.
time in each stage of the Pass
process
2.12
Manual Line: Continuously monitor time in
each stage of process.

CQI-12
Related
Question #
Minimum
Requirement
2.0 Cleaning / Descaling Solution
1.4
Pressure for spray rinse. Agitation with barrel
A2.1 2.11
Agitation for immersion tanks.
Automatic/Manual Automatic Once every 8 hours
rotation / Each order
Pass
2.12
Manually verified daily /
1.4
Conversion In Continuous monitoring by controller. Action Plan to automate
A2.2 2.11 Temperature Automatic Conversion In Process/Pass
Process/Manualon Manually verify daily. once work volumes
2.12
increase.
Chemical Concentration (Alkaline Cleaner) (If used)

Per chemical supplier recommendation such as:
1.4 - free alkalinity
For continuous operations, once per day.
1.6 - total alkalinity Percentage of cleaner /
A2.3
2.11 - pH
Automatic/Manual Manual Otherwise, prior to start of each
Start of shift
Pass
production cycle.
2.12 - conductivity
- percentage of cleaner (weight/volume or
volume/volume)
For continuous operations, once per day.

1.4 Chemical Concentration (Acid Cleaner) (If used)
Otherwise, prior to start of each Chemical
1.6 Per chemical supplier recommendation such as:
A2.4
2.11 - free acidity or concentration
Automatic/Manual Manual production day. (once per day for Concentration / Start of Pass
concentration, once per month for shift
2.12 - metal contamination
contamination).
Impurity Content
1.4
Per chemical supplier recommendation such as: Acid Split / Once per
A2.5 2.11
- acid split (oil contamination)
Manual Manual Once per week*
week
Pass
2.12
- alkalinity ratio
There is a tank maintenance schedule for cleaning

A2.6 2.11
baths.
Manual Manual Per preventative maintenance program Visual Condition PM Pass

CQI-12
Related
Question #
Minimum
Requirement
3.0 Rinse(s)
1.4
Pressure for spray rinse. Agitation with barrel
A3.1 2.11
Agitation or flow for immersion tanks.
Automatic/Manual Manual Once every 8 hours
Pass
2.12
1.4
Continuous monitoring by controller.
A3.2 2.11 Temperature (if controlled) Automatic N/A Rinses not heated. N/A
Manually verify once per day.
2.12
Cleanliness of last cleaner rinse

1.4
- alkalinity/pH/conductivity pH check to ensure that
A3.3 2.11
- visual inspection for oil or suspended contaminants
Manual Manual Once per day Pass
2.12 water flow is adequate
- overflow to maintain proper pH
levels / Once a day
A3.4 2.11 There is a dump schedule for rinses. Manual Manual Per preventative maintenance schedule. Pass
Visual Condition PM
There is a visual inspection (e.g. water break) after
1.4
A3.5 each post cleaning rinse bath (not applicable for Manual N/A Once every 8 hours Closed Barrels N/A
2.11
closed barrel systems).
1.4
A3.6
2.11
Corrosion inhibitor concentration is checked. (If used) Automatic/Manual Manual Once every 8 hours Titration Pass

CQI-12
Related
Question #
Minimum
Requirement
4.0 Acid Pickling
1.4
Start of each shift,
A4.1 2.11 Concentration Manual Once every 8 hours Once every 8 hours
Titration
Pass
2.13
1.4
Not Required per
A4.2 2.11 Concentration of Fe, per coating supplier. Manual Once per day Once per day N/A
Chemical Supplier
2.12
1.4
A4.3 2.11 Inhibitor (if used) Manual N/A N/A Not Used N/A
2.12
1.4
A4.4 2.11 Solution Level Manual Once every 8 hours Once every 8 hours Start of each shift Pass
2.12
A4.5 Rinse - See Section 3.0.
5.0 Aluminum Etching
1.4
A5.1 2.11 Concentration Manual N/A Once every 8 hours Not Performed N/A
2.12
1.4
A5.2 2.11 Concentrations of Al, per coating supplier. Manual N/A Once per day Not Performed N/A
2.12

CQI-12
Related
Question #
Minimum
Requirement
6.0 Aluminum Deoxidizing
1.4
A6.1 2.11 Concentration Manual N/A Once every 8 hours Not Performed N/A
2.12
1.4
A6.2 2.11 Concentrations of Al, per coating supplier. Manual N/A Once per day Not Performed N/A
2.12
7.0 Sealing Rinse (if applicable)
1.4
A7.1 2.11 Temperature (if applicable) Automatic N/A Manually measure once every 8 hours Chromic Seals Not Used N/A
2.13
1.4
A7.2 2.11 Concentration Manual N/A Once every 8 hours Chromic Seals Not Used N/A
2.12
1.4
A7.3 2.11 Solution Level Manual N/A Once every 8 hours Chromic Seals Not Used N/A
2.12

CQI-12
PROCESS TABLE C - Conversion Coatings (Phosphate, Non-phosphate, Chromate, Non-chrome)
Related
Question #
Minimum Requirement Actual Condition Minimum Requirement Actual Condition (Pass / Fail / N/A)
1.0 Conversion Coating
This audit requires the completion of either

C1.1 1.4
Table A and/or B.
n/a Table A n/a Table A Pass
If the pretreatment and phosphate is not a continuous

process, there shall be a part cleanliness check Every start of production cycle and
C1.2
immediately before phosphate. Acceptance criteria
Manual Continuous Line
change of lot number and each container.
Continuous Line Pass
must be defined.
Confirm set-up at the start of production Manually verified daily

1.4
and every process change. on Two Phos Lines.
1.6
C1.3 Time Automatic Conversion In Process Manually verify every 3 months or after Electronically verified on
2.11
programming change or equipment remaining two Phos
2.12
maintenance. Lines
Conversion In Process/Pass
2.0 Conditioner (If Applicable)
1.4
C2.1 2.11 Pressure/Agitation Automatic N/A Once every 8 hours N/A N/A
2.12
1.4 For continuous operations, once every 8
C2.2 2.11 Chemical Concentration Automatic/Manual N/A hours. Otherwise, prior to start of each N/A N/A
2.12 production cycle.
C2.3 2.11 There is a dump schedule for conditioner. Manual N/A Once per week N/A N/A

CQI-12
Related
Question #
3.0 Conversion Coating Bath
1.4
Agitation with barrel
C3.1 2.11 Pressure/Agitation Automatic Automatic Once every 8 hours
Pass
2.12
1.4 Temperature is monitored and controlled if required by

Manually verified daily /
C3.2 2.11 chemical manufacturer's technical Automatic Conversion In Process Once every 8 hours
Conversion In Process
2.12 data sheet.
Conversion In Process/Pass
Chemical Analysis:
Chemical concentration,
- Phosphate: Free Acid, Total Acid, Iron Content, pH,
1.4 pH checks completed
Accelerator Amount as Applicable
C3.3 2.11
- Non-phosphate: Concentration, pH
Automatic/Manual Manual Once every 4 hours every 4 hours or as Pass
2.12 production amounts are
- Chromate: Concentration, pH
processed.
- Non-chrome: Concentration, pH
1.4
Fluoride Ion Concentration (if aluminum is being
C3.4 2.11 Automatic/Manual N/A Once every 4 hours Don't Process Aluminum N/A
coated)
2.12
1.4
1.6 Start of each shift Per
C3.5
2.11
Coating Weight/Thickness Manual Manual Once every 8 hours*
ASTM B 767-88.
Pass
2.12
1.4 At Customer request
C3.6 2.11 Crystal/Grain Size (If applicable) Manual Manual Per customer requirement RTI Laboratories, A2LA, Pass
2.12 is utilized.
Coverage of phosphate coating is visually inspected

C3.7
for absence of voids.
Manual Manual Once every 8 hours Each Container Pass

CQI-12
Related
Question #
4.0 Rinse After Phosphate
Cleanliness of last rinse

1.4 Free Flowing/Self
- alkalinity/pH/conductivity
C4.1 2.11
- visual inspection for suspended solids
Automatic/Manual Manual Once every 8 hours Cleaning Rinses are Pass
2.12 used.
- verify water flow (1/shift)
1.4
Agitation with barrel
C4.2 2.11 Pressure/Agitation Automatic Automatic Once every 8 hours
Pass
2.12
Continuous Flow /
C4.3 2.11 There is a dump schedule for rinses. Manual Automatic Once per week Rinses monitored for Pass
dump schedule

CQI-12
Related
Question #
5.0 Sealing Rinse (if applicable)

1.4
C5.1 2.11 Pressure/Agitation Automatic N/A Once every 8 hours N/A N/A
2.12
1.4
C5.2 2.11 Chemical Concentration Automatic/Manual N/A Once every 8 hours N/A N/A
2.12
1.4 Temperature is monitored and controlled if required by
C5.3 2.11 chemical manufacturer's technical Automatic N/A Once every 8 hours N/A N/A
2.12 data sheet.
C5.4 2.11 There is a dump schedule for seal. Manual N/A Once per week N/A N/A
6.0 Dry-Off (If Applicable)
1.4
C6.1 2.11 Air temperature is monitored and controlled. Automatic Automatic Once every 8 hours Each Shift Pass
2.12
1.4 There is a procedure to ensure dryness of parts prior Every change of lot number and each
C6.2
2.11 to subsequent coating.
Visual Visual
container.
Visual Final Inspection Pass

CQI-12
PROCESS TABLE K - EQUIPMENT
* When historical results show capability, test frequency may be reduced.
Related Pretreatment/ Calibration / Included in

Powder
Item # CSA Equipment Type Aqueous E-Coat Spray Dip/Spin A-Coat Cure Anodize Verification Frequency Certification Preventative Comment
Coat
Question # Cleaning Frequency * Maintenance Plan
PROCESS EQUIPMENT
K1.1 2.14 pH / Conductivity Meter X Daily Quarterly Per Discharge Permit
pH / Conductivity Probe N/A

K1.2 2.14 Solution compatible probes X Nper Lot Control/Expiration N/A
must be used.
K1.3 2.14 Temperature Controller X Annual Annual/External N/A
K1.4 2.14 Rectifier N/A N/A N/A
K1.5 2.14 Amp Meter/Volt Meter N/A N/A N/A
Wet Analysis: Daily

Before use, chemicals must be
K1.6 2.14 X Daily N/A
checked for shelf life and/or
expiration date
K1.7 2.14 Filters X Daily N/A Bi-Weekly
Laboratory Balance (Weight N/A

K1.8 2.14 X Annual Annual
Scale)
K1.9 2.14 Conductivity Meter N/A N/A N/A
K1.10 2.14 Viscosity cup N/A N/A N/A
Annual
K1.11 Thermocouple X Daily Annual/Internal
K1.12 2.14 Lab Oven Controller N/A N/A N/A
MINIMUM REQUIRED TESTING CAPABILITY

OffSite accredited Off-site Lab Utilized
K2.1 2.14 Salt Spray Cabinet Per Cust. Reqmt.
Lab
K2.2 2.14 Water Immersion bath X Daily N/A N/A
K2.3 2.14 Cure Testing Per Part N/A N/A
K2.4 2.14 Adhesion Testing As Required N/A Off-site Lab Utilized

Cal.Analytical N/A
K2.5 2.14 Coating Weight Testing Phosphate Bath Output / Daily
Balance
K2.6 2.14 Solids Testing N/A N/A N/A

CQI-12
PROCESS TABLE L - Part Inspection and Testing
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to specifications or other
requirements.
Note that not all tests are applicable to all coatings.
Related
Item # CSA Category/Process Steps Monitoring Frequency Observation/Comments
Question #
Minimum Requirement Actual Condition (Pass / Fail / N/A)
1.0
Procedures are in place to prevent damage to the finish or part

L1.1 1.4
during the inspection and packaging processes.
System in place System in place Pass
Sampling Level, 20
Appearance of the coating shall be verified per specification and
L1.2
applications manual.
Ongoing Pcs/Container: Per JTF 096-1.0 Pass
Final Inspection
Initial adhesion At the start of production and once every Tape Test used per Specification
L1.3
(Tape, bend, impact) 8 hours. requirement.
Pass
Visual Inspection per

L1.4 Intercoat / final adhesion Per customer specification
Specification
Pass
At the start of production and once every At the start of production and
L1.5 Color and Gloss (If applicable)
8 hours. once every 8 hours.(Black Phos)
Pass
At the start of production, every

At the start of production, every part family
part family change and every
L1.6 Film thickness / coating weight change and every process change. Once
process change. Once every 8
Pass
every 8 hours.
hours.Per ASTM B 767-88.

CQI-12
PROCESS TABLE L - Part Inspection and Testing
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to specifications or other
requirements.
Note that not all tests are applicable to all coatings.
Related
Item # CSA Category/Process Steps Monitoring Frequency Observation/Comments
Question #
Minimum Requirement Actual Condition (Pass / Fail / N/A)
Once per week per line per coating

Corrosion resistance: process being used.
- Neutral salt spray If the same coating system is used for Per Customer Requirement. Off-
L1.7
- Humidity multiple customers with different Site Accredited Lab is utilized.
Pass
- Water immersion requirements, test to the highest
requirement.
Utilization of Line Oils with

Once per week per line per coating
L1.8 Torque tension/Coefficient of Friction known values of Tension and N/A
process being used.
Coef. Of Friction.
L1.9 Dimensional check (e.g., Go-no go, Plug and Ring gage) Per customer specification Per Customer Requirement Pass
Review of Quote/Prints for

L1.10 Hydrogen Embrittlement Per customer specification N/A
Rockwell C Scale/38 or lower.
L1.11 Cyclical Corrosion Testing Per customer specification Not requested or performed. N/A

Cqi 12

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CQI-12v2

Special Process: Coating System Assessment

AIAG Copyright and Trademark Notice:

© 2012 Automotive Industry Action Group

© 2012 Automotive Industry Action Group

Special Process: Coating System Assessment 2nd Edition

Facility Name: Jackson Tumble Finish

Phone Number: (517) 787-0368 Type(s) of Coating Processes at this Facility:

Date of Re-assessment (if necessary):

Number of "Not Satisfactory" Findings:

Number of "Needs Immediate Action" Findings:

Number of "Fail" Findings in the Job Audit(s):

Number of Process Table Items not meeting Minimum Requirements:

© 2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment (General Facility Overview)

Question Not Needs Immediate

Section 1 - Management Responsibility and Quality Planning

1. Daniel Guerrero (Production

The coater shall incorporate a documented advanced

© 2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment (General Facility Overview)

Question Not Needs Immediate

1. Process FMEA up-to-date reflecting

The coater shall incorporate the use of a documented

© 2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment (General Facility Overview)

Question Not Needs Immediate

1. Standards and requirements are

The coater shall have written process specifications

© 2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment (General Facility Overview)

Question Not Needs Immediate

1. Process capability studies are

© 2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment (General Facility Overview)

Question Not Needs Immediate

1. Internal assessments are completed

The quality management system shall include a

© 2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment (General Facility Overview)

Question Not Needs Immediate

1. Continual Improvement Procedure

Does the Quality Manager or

There shall be procedures or work instructions 1. Work Instructions (CD-019) available

1. Training Procedure 6.2

© 2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment (General Facility Overview)

Question Not Needs Immediate

The coater shall maintain a responsibility matrix 1. Responsibility/Training Matrix is

1. Preventive activities are performed

Has the coater developed a

© 2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment (General Facility Overview)

Question Not Needs Immediate

Section 2 - Floor and Material Handling Responsibility

Out-going lot(s) shall be traceable to the incoming

The control of suspect or non-conforming product is 1. All stages, from receiving,

© 2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment (General Facility Overview)

Question Not Needs Immediate

1. Processing container inspections are

Loading parameters shall be specified, documented

© 2012 AIAG (Automotive Industry Action Group)