CQl-15 Special Process: Welding System Assessment 2nd Edition NAA eR] EyesAIAG Spec Pcs: nein yom scene ABOUT AIAG Purpose statement Founded in 1962, AIAG isa globally recognized organizaton where OEMs and suppliers une to adcress| and reso issues atfecing ine vordvice automebve supply chan, AIAG s goals are to reduce cost anc Compiouty though colaboraton improve procuctquaity, neath cafe anc tho onvonmont, ang oplmize speedo matkat twoughout the supely chan AIAG Organization ‘AIAG Is mage up of boats of atecoss, an execulve Gracor, execullves on foan fom member Companies, associate declors. 2 fab staff-and volunteers serving on project ears Dears Gepertment managers, ané program managers plan direct anc coordinate ihe association's activites Uundor mmo aes oho evecutvo areceor AIAG Projects \Voluntaercommitoas focus on businss procossoc or supporting technologies and metrodclogce. Thay conduct research and develop, publsh, and provide taining on standards, converiton, standard business practices, while papers, and gurdeines in the areas of automat identification, CADICAM Ebielectrone commerce. coninuous qualty improvement, neath focus, matenals and orfect managemont. cezupational noah & safty, rotumabie containers anc packaging systoms, Wanspocatoneustoms and Vuck & heavy equipment ‘wistence cf AIAG publicabon does net n any rapes! pret anyone fom merufstunng, madre, fchoang sunny pric pccsses or posers no! norma he lene AKG picasa ute 0 prea rete end were suse On et ees -asogrong ha ma IAS pain rn a oer a ertenes AAS pa entannas marr prt Passer harinarce Meas arin ttn onan ones eae Automobre lndcaty Aeon Or Prone: (25) 8 I8r0 Pe (0) 2682 The AKG Quay Seeing rite ord deste cnabokar areas i cure pct. on pease rye orn ntti cena peony 8. Boe) Sines Gavin SiS imo oe ESE an Siena iy ory ote cence es aes mes (peer St a Sep Coen ene aha oo incur Seer Se nals ro clam io ay Uadevel bird pot ademataol Pps nce rbese mars 210 Acomatie neue Aten Cre wee 1 soe asacals Sh ates owe AIAG 2» CHANGES MADE TO CQ/-15 2"? EDITION, 2" PRINTING The following comections were made tothe COI-15 2 edition, 2 printing 1. Job Audie Process Tables, Sesto 2 Cont Pian 1d Lot Contieaeat ~All welé valiStion tstng sell be performed prior to shipping (Gach & Hes) Changed to— Weld Lot Containmeat ~ Ail eld validation testing shall be peefoamed prir to shipping ‘components with critical (CC) welds Batch & Hl). 2. Drawn Are Job Audit tab item 4.6 (Control Limite ~ Control limits shal be ulized for controlling eninimsa load requirements Changed to ~ \Wasning Limits — Warning Lt aall be wUlize for controling the weld atibut \Wasning Smits to establish aa alert price to fue to aueet specifications 3. Resistance Welding Tob Audit ab, tems 7.3 and 75 are dapicata and willbe combined into 73 7.3 Par toaching detail, locating pine, fimae locator and tooling mating surfaces ~All etal: checked for Iooveness ll aoa pinned details orque checked and atch marked 7.5 Past touchine dati, locatarg pian, Sista locator and tooling metiae aefaces All sting surfaces shall be fee of expulsion ad debris, (Changed to — 7.3 Part touching details, focating pins, fixture locators and toting mating surfaces— All Getals checked for Tooseness, all non-pined details torque checked and match marked, ‘Ail mating surfaces stall be fee of expulsion and deie (© Trem 75 willbe deleted. edition and the COT-15 2 exiton, * | Note: For auditngassessing puposes the COL Printing are considered equivalencal-15 AIAG Special Process: Welding System Assessment a» en Ping en anny FOREWORD Automotive Industry Action Group (ATAG) committes ate made up of voluteers fom member ‘companies inthe automotive indstry. The wrk of preparing process audits is done by ATAG technical commits “The asia tak: of tachaicalcomantees isto prepare Automotive Standards and System Requiceneat, raft document adoptes by the technical comauttacs are circulated to the Steeitg Commas Zor giew ‘aud coseenras approval. Publication ofthe dovutmenteregutes approval by the Quality Steering Commie, ‘The Quality Steering Commitee would like to acknowledge and thank the following inviduals and their companies who hove contnbsted time and effort tothe development of this document ACKNOWLEDGEMENTS Dave Wiig Nestosr Automotive ~ Chair Brian Hable Ford Motor Company -Co-Chaic Davia Weatherly Adiaat USLLC Marshall Sayre Dana Incorporated ‘Wayne Sozaniky Delphi Techaslogiet Joseph Beckham FCAUSLLC Coxy OBrien FeAUSILC Mare Gtting Ferd Motor Compaay Ricky Boudry General Motors Company Joka Writ Gestamp Mason Heavish Mistry ‘Magna International ‘area Kratieh AIAGCcQl-15 ‘Special Process: Welding System Assessment TABLE OF CONTENTS ABOUT ARG nn (AMES MADE TO COL-5 2" EDITION, 2" PRITING ACKHOWLEDGEMENTS se TABLE OF CONTENTS. nena. AsseionQusurarons (Omen Rroumeewrs aiéees, 2. THE WELDING SYSTEM ASSESSMENT PROCEDURE von 2.Lingmacrovsrot nie Suvanan rennin Secno8 2.2ixgmecrovsror ne Waa Sema Aas 2 ahkerveroveror neon Auer Proce doe Aver Poses Tat 25 Wane SuaransouT Hawa Cor GLOSSARY.AIAG writin nr to INTRODUCTION General The work of preparing CQI-15 Special Process: Welding System Ascessment (FSA) 2 edition was completed by the AIAG Welding Work Group. These welding requirements are complementary customer and product standards. The WSA cat be weed toasters an orgatizatices ability to meet te requirement ia thie ssetement, 32 swell az customer, egulatory, and the organization's owa requiemetts. Tze WSAL ean also be used between en organization adie supplier. In the WSA, the word “shall” indicates a requirement for purposes ofthe seiFassessment The word “should” indicates a recommendation. Where the term “such as" is ured. any suggestions given ae for guidance cay Compliance tothe WSA is determined uring te table belo ‘Does NOT meet i requirement, need: immediate actin Any RED Element | Process even isis that thee a sk of oce-contoniag produc ‘Doe: NOT meet de requirements coxlaomeat bin place. GREEN 0-RED | Process review indlcates hat Chere venoneh ccteoent of note soufomaig product 100% GREEN Mest equirements Process Approach ‘The WSA soppotts the autometive process approach as described in IATE 16949, Welding System Assessment Goals ‘Tho goal ofthe WWSA isthe development ofa welding management ete tat provides for eostiavel ‘provement emphasizing defect prevention andthe eduction of varution aud waste ia the suppiy chain. The WSA, coupled with an intecationally recognized quality management system and applicable customer specific requizements, defines the fundamental requirements for welding management eyes. ‘The WSA is intended to provide common approach to a welding management system for automotive production and cerice part srzenizasons Assessment Process Ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to reexamine the continuing compliance withthe WSA. Each atssement shall clude a revi of toeCaQl-15 ‘Special Process: Welding System Assessment AIAG >» organizetion' eytems using the WSA. Succectve fob Aasite shall sump pots Som dffercat autemetive component manufacturers tha require compliance tothe WSA docamest. The assessment shall use the process approach to aitng/asessng as identified bythe requirements of IATF 16940, Assessor Qualifications Assessors) shall have the following specifi experience to conduct the WELDING SYSTEM ASSESSMENT: 1, Be en experiazced quality managemeateystem (QMS) intemal sudster (or example latest ection of LATE 16949, 180 9001), 2. Asserzoe shal paris: welding inowledge. Fvideare sll include a mizieas of 5 yeart bsperience in welding ors combination of formal eGuostion ia welding and welding seperience touaing a minimom of 3 yaar, 3. Assessor shall possess knonledze of and be familar withthe application of automotive quality cove tole including tatistical proces conte, measuretnent ster aay art approval, fiture mode and effects analysis, and advanced quality plang, Note: 1fmore than one assessor is requited to meet the shove qualifications, the lead assessor shal be the persoa masting the requirements in #1 Other Requirements ‘The organization shall Keep records at evidence cf complianse tothe requremasts identified ia tha WSA, ae well ar all appropsiae action plan to addreee any nonconforming rags, These rerords sail be feadiy avaiable for eview by aay customer raquting compliance tothe requicement within thi. ‘documentcal-15 AIAG => ‘Spocia Process: woluing Systom Assessment 1 SCOPE 1.4 General ‘This deoument specifies procsnesequtements for au organization or te avplier parfoaming applicable fero9s and no ferro metalic welding, Who 200d to: 4 demonstrate ability to coasitently provide prod regulatory requirement, 2a 4+ cance customer satisfaction trough the effective application ofthe eyrem,icloding ‘processes for coatauel amprovenient ofthe syste. that meets customer aad applicable ‘The Welding System Assessments applicable to sites where customer-speifie pats for proguction andior service are processed throughout the automctive supply chain 1.2 Application All sequirements ef the CQI-15 Welding System Assessment are generic ad ae intended to be applicable to all organizations performing the welding operation adessed inthis document, regardless of ype size, and product. Eight Job Audit Procens Tablos have boss devaloped end the appropriate Job Auda() i to be completes carne the assrement. The Job Audt Process Tables ate sponte to welding processes ts asted blow Gas Metal Are Welding Flux-Cored Arc Welding Gas Metal Are Welding Shieldee Metal re Weleing Plasma Are Welding Gas Tungsten Ate Welding Gas Metal Are Braze Welding Laser Deam Welding + Lae Seam Welding Drawn Are Welding + Arc Stud Fastener Welding Resistance Welding Rexiaance Spot Welding Resistance Seam Welestg ‘Masa Seams Welding Flash Welding Projection WeldingCQl-15 Sse recy aay nen AIAG Eviction Welding Does ac iaclade Friction Ste Welding ‘+ lena Friston Welding 4 Dinect Drive Frition Welding Inducton/Hish Freaueney Tabe Welding ‘© Tiph-Frequescy Seam Welding Tection Seu Welding, Fastener Projection Welding ‘© Projection Wei Magnetically Inpelled Are Dutt (MIAB) Welding ‘hove Job Audit Procers Tables contain rguicement fr: 1 Part Print Control Plan Destructive & Nondestructive Testing Data Weld Quality laspecion & Reports Rework Procedute & Reports Perameter Docomantatice Maintenance Records Sustainability ‘Equipment & Robotic Processing Requicemeats omer 1.3. Reference Tho folowing standard oro used as seference material. There ae ther reference atonal thet esata, snore information, however, te st is not atatt to be atclasive. The applicability ie Lite to the abject ‘maser reference. Standard Number | Title ‘Standard’s Organization ANSIZ49.1 Safety ws Welding ond Costing ANSL- wens AWS A390 Standard Welding Term and Definitions | wusawe.org AWS ADS Standard Weld Symbstogy ‘weve anes orgcaQl-15 AIAG Se A 2 THE WELDING SYSTEM ASSESSMENT PROCEDURE System Assesment call nclude aeviow of the cxgeatzation'seyatem wuss tke Weld pmcet tab ead tha arpropnate Jeb Audit Process Table lected ia tao Excol Sle Soccessve assessments sll sample pars ffom different automotive component manufactrers that require compliance t the Welding System Assessment ‘Oagoing asesemeat: shall be conducted aamually,nales ocherwise specified by the customer, tor ‘examine the continuing compliance with the Welding Sytem azzssement, ‘The erganization shall keep cecords es erideace of compliance tothe requirements identified inthe WSA, satwell as all approprinte action plas to address au seis that do an meat the requurements witha this ocumeat. These cecords shall be readily avaiable for seview by any customer requting compliance to dhs docamaect 1. Download aad save the Excel ile that contains the COUL1S Welding Systom Assessment by felling the steps below ‘© Goto wow aiag ong 4 Enter your uremame & pansword # Goto Ab desount = Fer-an eDocument purchase: goto eDocioments Select ddsitional Docioarie ~ Fora Hardcopy purchase: goto Downloads 2. Severe Excel le that contnine the CQL-1S Welding System Assessment 26 Supplier Name Site Code Country. State_City_Vear Month Day_Weld Ascessmentxisx Please note thatthe assessment can only be downloaded from the account it was purchased under. { Note: Due tothe complet ofthe Welding System Assessment Excel file, itis recommended ‘a2 fil outed foreach 2.1 — Instructions for the Summary Information Section (Fab 1 of Exe Fle) 1. Supplier Name and Address: Naate aad addvess ofthe ficilty being assessed. 2 One form shall be sed fx each fociiy. The Mciity may have several buildings or ‘physical locations in the same geanral area, Lethre isa separate management tact of fiferent management syst, then there cations shall be considered as separate relives 2. Site Code/Parent Code: Enter ste code of fei boing aeeseed. 3. Current Quality Certfiation(): The weld organization shal Sst their coment quality cenications, eg, [ATF 16948, 150 3001. Cerications may be from Src party sources oF customer quality certifications 4 Date of This Acsesement: Ectrthe dates) ofthe anesamens. Use format that will avid confusion. Example: November 3—4, 2018,5. Date of tntia Ascecement(s): List tho dato ofthe instil Speetl Process: Welding Sytem Assessment completed at this feet 6 Date of Re-Assessment ifnecessary):IF*Yellow” or “Red” findings were observed ftom the initial assessment, then the weld organization shall address each item and determine corective action(s) including root cause alysis and implementation ofthe corresponding covrestive Number of Welding Fmployees at this Facility: The sumer of employees, salavied iad hourly, associated with dhe welding operstion at this Pci. Captive Weld Organtzstion: Eater "Ves" if ths facility welds components complete in that ‘eilty, Enter “No” ifthe compaty receives ony ¢ob ter weldment fom outids thet company both condition exiet ater “No” 9. Review Members/Site Responsible Person: List the anes) title(), email addreso(s), and Phone aumber(3), end if available, ofthe prncical parcspents from the weld organization. Tae site responsible pessoa isthe persca fom the customer who is espeauible fr that location 19. Suppli 1, Weld Classifications: Litt ald elatiication of pa being aucencd, 12, Welding Processes Used: List ll welding proceas(es) performed a thi fecility. This saformaticn determines the appropriate Job Audit Process Table that shold be used during the ‘ssseusmont Procazsee act listed ia thes section are ast part of to Welding System Anoteement, 13. Weld Specifications Useds List weld specification used for part being assessed 11. Commodity Code: Pik ftom drop down list, or add your own code, if needee 15, Part Numabor(s) Assess + Contacts List the name(s), tle), email adresses), and phone number). at pet umber, veicl/progcam and product informetioe f part ‘Summary Information ‘The bottom halo the Summary Information sheet is an overall “map-shot” of compliance tothe Weld System Assessment andthe Job Audit). The data inthe scoring ceils will populate automatically as you complete the Weld System tb and appropriate Job Aust Process tab(3). ‘Tne purpose of thie section ito ansst an orgatizatioa ia identifying areas thet may need eddivonal resol to enhance theic compliance to the Welding System AxsasementAIAG CQi-15 Special Process: Welding System Assessment ie te Assent wary on ] ‘canna Teese mcr mo Sears Tamrac oa Geeta seo ‘enone cerry Te [eratzcane ro larg eaten Us emmmeenyismer: nce gan wfmstn [rt Sma commen22 _ Instructions for the Weld System Assessment (Tab 2of Excel Fe) ‘Weld Sytem Assonoment cots five sections consisting of questions with requirements abd guidance foreach question to arta datecmining compliance, ‘The Sections are Section 1: Weld System Procets Aseeesieat Section 2: Documentation Section 4: Preplanning / Quality Documentation Seetlon 4: Production Moaitring | Documentation Section §: Ratvors or Scrap Procedure aad Reporte ‘The assess shall assess the weld organization compliance to Sections I~ 5 by comparing the cvidence preseated bythe Weld organization to the requirements Led in the “Requuenents abd Guidance™ column, I he observed evidence isin compliance to the question, the aseesc shall aoe the evidence i te “Evidence Gap dectfed” colon ad velet “green” inthe “Testial Rating” colvna (Af theft ‘the firsvoriginal ascessment for the process) Toe "Corrert Stas” coum will utonatically populate The observed evidence ie not in compliance tothe question, thn the aecssor sul act dhe non compliance in the “Evidence/Gap [dented cofummn and select “yellow” or “red” inthe “Titial Rating” column Qf this ete freorigial asessment forthe process) The “Curren Status” colusia will automatically poptate + “Yellow” items do act mest the requirement Process ceview indicates thatthe s soflcieat containment of woa-sontormiag prodact. 4 "Red" ems do not meet equicemente, Process revs indicates that here teria of conforming product and needs immediate action. Adéres each “yellow” and “red” tem aad determine corrective aston, incloding root ca cnnlyss and plementation ofthe covrespondiag cemectiveactioa(s). The corrective etcals) shall be completed within 9 days Records af the comective action, including verification hal benaitained. Ishi is NOT the frig! azesement forthe process, eave the origiaal score (gree, yall cr faq) athe “Tastal Rating” cohuma and select he appropriste sare (green, ellow ceed) 2 "Cusrent Stass™cofusa only. Tie will enable the ganization o messes their perfomance Ifthe question is ot applicable tothe weld crganlzation then the assessor shall place “N/A in te “Enidenco Gap dactied” colsme Ansccoments shall be conducted enauelly wales ctherwive specified by the customer. ‘Note: The Initial Ratz csloms should be used daring the at original assessmast oa