Cqi - 12 - Audit Report of Aum Dacro 24.06.2023

Special Process: Coating System Assessment Version 3 Issued 07/2020
Special Process: Coating System Assessment Cover Sheet
Facility Name: Aum Dacro Coatings

Address: Plot No. 04, Sector -06, IMT Manesar
Gurugram,
Haryana -122050 (India)
Phone Number: -
Current Quality Certification(s): IATF 16949:2016 & ISO 9001:2015
Number of Coating Employees at this Facility: 190
Captive Coater (Y/N): N
Commercial Coater (Y/N): Y
Date of Assessment: 24/06/2023
10.03.2022 -11.03.2022 (Self Assessment by
Date of Previous Assessment: Supplier)
Date of Re-assessment (if necessary): -
Type(s) of Coating Processing at this Facility:
Process Table A: Applicable Process Table G: Applicable
Pre-treatment (Aqueous) Dip Spin and Zinc Flake
Process Table B: Applicable Process Table H:
Pre-treatment (Mechanical) Autodeposition
Process Table C: Process Table I: Applicable
Conversion Coatings Cure
Process Table D: Process Table J:
Powder Coating Anodizing and Hard Coat Anodizing
Process Table E: Applicable Process Table K: Applicable
Spray Coating Equipment
Process Table F:
Electrocoat
Personnel Contacted:
Name: Phone
Auditors / Assessors:
Name: Phone
Mr. Akash Upadhyay 8400258501
Mr. Sumit Dhariwal 9306206855
Number of Nonconforming Findings from Section 1 and Section 2: 0

Number of Nonconforming Findings in the Job Audit(s): 0 0
© 2020 AIAG (Automotive Industry Action Group)

Number of Nonconforming Findings in the Process Table(s): 0

CSA SECTION 1 - Management Responsibility and Quality Planning
Management Responsibility and Quality Planning
1.1 There shall be a dedicated and qualified surface finishing person on site.
• To ensure readily available expertise, there shall be a dedicated and qualified surface finishing person on site.
• This individual shall be a full-time employee and the position shall be reflected in the organization chart.
• A job description shall exist identifying the qualifications for the position including coating and surface finishing knowledge.
• The qualifications shall include a minimum of 5 years’ experience in surface finishing operation or a combination of a minimum of 5 years of relevant formal
education and surface finishing experience.
Conforming
Guidance Objective Evidence Nonconforming
NA
What is this person’s title? Quality Head - Mr. Saurabh Kumar Conforming
Yes, Annexure 1 of Quality Manual, Rev. 0,
Is this position reflected in the organizational chart? 15.11.2018 last updated on Date 02.01.2023 Conforming
Is there a documented job description listing all the required qualifications and Available amd evident with format no. F01 (MR-P-
responsibilities of this position? 14, Rev.0 last updated on 02.02.2023) Conforming
B.Tech Mech with 10 years experience in Geomet

Describe in detail this person’s educational background and practical experience. Conforming
coating application
How many years of process experience at a coating facility does this person have? 10 Years Conforming
Is this individual a full-time employee at the location being audited? Full time employed Conforming
Comments: Ok
Section 1 - Management Responsibility and Quality Planning

1.2 The facility shall perform advanced quality planning.
• The organization shall incorporate a documented advanced product quality planning process.
• A feasibility study shall be performed and internally approved for each new part or process. Similar parts can be grouped into part families for this effort as
defined by the organization.
• After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer.
• The organization shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.
Conforming
NA
Yes, procedure for APQP QAD-D-09 is available and

Does the facility use a documented advanced quality planning process? evident with latest Rev.04, & Date 10.10.2022 Conforming
Does the facility perform a documented internal feasibility study for each part before
Yes Feasibility study report F03(QAD-P-09) Rev. no.
processing?
01, Dated 26.02.2021 was evident for part Ball pin Conforming
If no, does the facility perform a documented internal feasibility study for similar part types
threaded M10x1.5. done on Date 14.01.2023
or family of parts before processing?
What is the procedure for changing the process after PPAP? ECN conforming
Comments: OK

1.3 The facilities FMEAs shall be up to date and shall reflect the current process.
• The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) and ensure the FMEAs are updated to reflect current
part quality status.
• The FMEA shall be written for each part or part family or they may be process-specific and written for each process.
• FMEAs shall address every process step from part receipt to part shipment.
• A cross-functional team shall be used in the development of the FMEA.
• All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.
Conforming
NA
Production - Abhay Singh

Yes, F06 (QAD-P-09) Common PFMEA was evident
Does the facility have a documented Failure Mode and Effects Analysis (FMEA) in use? Quality - Saurabh
last revised Kumar with rev. no.17 for double
on 01.05.2023 Conforming
QMS-
dippingYogesh
process.
Incoming Inspection - Neeraj Kumar
Final Inspection - Anil Mishra
Laboratory - Swati Verma
Identify the names and job function of the team members used in the development of the
Maintenance - Rakesh Kumar Conforming
FMEA.
Degreasing - Sudhir Kumar
Shot Blasting - Avenendra
Coating - Nitin, Satyam
Identify if the FMEA is written for each part, part family or process specific. Evidental
Packing and FMEA was Process
Dispatch - Mohitspecific
Verma for all parts. Conforming
Operations - Subhasis Datta
Yes, F06 (QAD-P-09) Common PFMEA was evident,
Are all FMEAs consistent with all associated documentation such as control plans, work
in control plan process steps was same according to Conforming
instructions and shop travelers?
FMEA and PFD.

Yes, F06 (QAD-P-09) Common PFMEA was evident,

Do all FMEAs include every process step from part receipt to part shipment? in control plan process steps was same according to Conforming
FMEA and PFD.
FMEA F06 (QAD-P-09) verify for special

Are special characteristics, as defined by the organization and its customers, identified,
characteristics , Part coating weight was show Conforming
defined, and addressed in the FMEAs?
critical in FMEA and control plan.
Yes, F06 (QAD-P-09) FMEA was revised for double

Provide evidence that the FMEA has been updated in response to quality issues. dipping process regarding customer complaint rec. Conforming
from customer.
Comments: -


1.4 The process control plans shall be up to date and shall reflect the current process.
• The organization shall incorporate the use of a documented control plan and ensure the control plans are updated to reflect current controls.
• The control plans shall be written for each part or part family or they may be process-specific.
• The control plans shall address all process steps from part receipt to part shipment and identify all equipment used and all key surface finishing process
parameters as defined by the organization.
• A cross-functional team shall be used in the development of control plans, which shall be consistent with all associated documentation such as work
instructions, shop travelers, and FMEAs.
• All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the control plans.
• The control plan shall detail the product and process characteristics, and controls including testing frequency and sample size.
Conforming
NA
Yes, Common Control plan, F01(QAD-P-09) Rev.15,

Does the facility have a documented control plan in use? Conforming
15/06/2023 was evident.
Identify if the control plan is written for each part, part family or process specific. Process specific - Common Conforming
Do all control plans include every process step from part receipt to part shipment? Yes Conforming
Does the control plan identify all key surface finishing process parameters? Yes, Conforming
Production - Abhay Singh

Quality - Saurabh Kumar
QMS- Yogesh
Incoming Inspection - Neeraj Kumar
Final Inspection - Anil Mishra
Laboratory - Swati Verma
Identify the names and job function of the team members used in the development of the
Maintenance - Rakesh Kumar Conforming
control plan.
Degreasing - Sudhir Kumar
Shot Blasting - Avenendra
Coating - Nitin, Satyam
Packing and Dispatch - Mohit Verma
Operations - Subhasis Datta
Are the control plans consistent with all associated documentation such as work
instructions, shop travelers, specifications and FMEAs? Yes Conforming
Provide evidence that sample sizes and frequencies for evaluation of process and product
Yes, addressed in control plan. Conforming
characteristics are addressed and consistent with the minimum requirements.
Are special characteristics, as defined by the organization and its customers, identified, Yes, Coating weight is defined as a special
defined, and addressed in the control plans? characteristics. Conforming
Provide evidence that the control plan has been updated in response to quality issues,
Yes Conforming
customer requirements and process changes.
Comments: Ok

All surface finishing related and referenced specifications shall be up to date and available. For example: SAE, AIAG, ASTM, General Motors, Ford, FCA, Toyota,
1.5 Volvo Truck.
• A document control system is pertinent for the handling and internal distribution of received customer specifications and to keep up to date with national or
global standards related to surface finishing processes. To ensure all customer requirements are understood and satisfied, the organization shall have all related
surface finishing and customer referenced standards and specifications available for use and a process to ensure that they are current.
• The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards and
specifications and changes based on customer required schedule. This process shall be executed as soon as possible and shall not exceed two weeks.
• The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how
they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the
two week period.
• The organization shall identify who is responsible for performing these tasks.
Conforming
NA
Yes, Customer standard and specification are

Does the organization have all related surface finishing and customer referenced standards
available. Conforming
and specifications available for use?
Customers are providing the standards &

How are standards and specifications obtained? Conforming
specifications
Describe the system and timing used to maintain the standards and specifications to ensure Control of Document procedureMR-P-01 was
that they are up to date. evident for Yearly standard review system Confirming

New standard & specification are being received by

Marketing dept . Marketing dept is sharing these
Define that process used to review and communicate within the two week period updated
with Quality Head & QMS Head. QMS Head is
standards and specifications throughout the organization. Include the names and job Confirming
updating the same and communicating to concerned
functions of the responsible personnel.
dept.
Comments: ok

1.6 There shall be documented process instructions.
• The organization shall have written process instructions for all active parts or family of parts, including relevant part specific requirements. Examples of part
specific requirements include process line, coating type, load size, rectifier settings.
• These process instructions may take the form of work instructions, job card, computer-based recipes, or other similar documents.
Conforming
NA
Does the organization have written process instructions for all active parts or family of parts Available in tracking card. - Part specific Tracking
Conforming
and include all relevant operating parameters? card with Process parameters - F01(QAD-P-05)
What form of process specification is used? (These may be in the form of work instructions, Work Instructions, Tracking card/Job Card,
job card, computer-based recipes, or other similar documents.) Computer based recipes, Conforming
Comments:Ok

1.7 A valid product capability study shall be performed.
To demonstrate each process is capable of yielding acceptable product, the organization shall perform product capability studies for the initial validation of each
process, after relocation of any process equipment, and after a major change of any process or equipment. The organization shall define what constitutes a
major change.
• Initial product capability studies shall be conducted for all surface finishing processes per line as defined in scope of work and in accordance with customer
requirements. Capability study techniques shall be appropriate for the surface finishing product characteristics, (e.g., surface finishing thickness, corrosion
resistance, etc.).
• An action plan shall exist to address the steps to be followed in case capability indices fall outside customer requirements or established ranges.
Conforming
NA
Has an initial product capability study been performed? Yes, validation is done for all process Conforming
Are studies conducted for each surface finishing process for each line in the facility? Yes, product performance in checked for all lines. Conforming
Has a new study been completed after relocation of any process equipment, major rebuild Yes, validation is being done after re-location or
Conforming
of any equipment, or any significant change in process chemistry? modification.
Change is happened in process or machines. All are

How does the organization define what constitutes a major change? Conforming
addressed in 4 M change.
Analysis and corrective action and effectiveness

What steps are followed when capability indices fall outside specified requirements? checking Conforming
Comments:Ok

1.8 The organization shall collect, analyze, and react to product and process data over time.
• The analysis of product characteristics and processes parameters over time can yield vital information for defect prevention efforts.
• Methods of analysis shall include ongoing trend or historical data analysis of special product and process parameters.
• The organization shall determine which parameters to include in such analysis.
Conforming
NA
What product characteristics and process parameters are used? All control plan parameters are recorded. Confirming
How is the ongoing trend or historical data reviewed and analyzed? daily and weekly review done Confirming
How does the organization use this data to prevent future failures and improve the quality
Implementation of CAPA Confirming
system?
Comments: ok

1.9 All process control and testing records must be retained for a minimum of one calendar year after the year in which they were created.
Conforming
NA
Records are retained as defined. Minimum 3 years -

What is the process to retain these records? Master list of Record Retention is defined(F05(MR- Conforming
P-01))

What is the process for retention of customer specific documents with longer retention
times? Maintained Hard & Soft copies Conforming
Comments: OK

1.10 There shall be a process in place to review the monitoring systems / logs at specified intervals.
• Management or management designee shall review the monitoring systems / logs at specified intervals.
• The organization shall have reaction plans for nonconformances to process requirements.
Conforming
NA
MIS - Controlled through HMI - logs are being
Define the process in place to gather and review this information. maintained Conforming
Identify the manager or management designee reviewing the process records from the
monitoring systems / logs. Departmental head is reviewing the process records Conforming
Describe reaction plans for nonconformances to the written process requirements. Reaction plan mentioned in control plan Conforming
Comments: ok

1.11 Internal assessments shall be completed at a minimum once every 12 months using the latest revision of the CQI-12 coating System Assessment.
Conforming
NA
This is the first internal self assessment done on

What is the date of the last AIAG CQI-12 coating System Assessment? 10.03.2022 -11.03.2022 and customer assessment is Conforming
done on 24.06.2023
Comments: ok


1.12 There shall be an internal system in place to authorize reprocessing and it shall be documented.
• The quality management system shall include a documented process for reprocessing that shall include authorization from the quality manager or a
designated individual.
• The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is
not permissible.
• All reprocessing activity shall require a separate rework specific process control sheet or other identification method, issued by qualified technical personnel
denoting the necessary surface finishing modifications.
• Records shall clearly indicate when and how any material has been reprocessed.
• The rework of material shall comply with the customer’s specifications and / or requirements.
Conforming
NA
Describe the procedure for authorizing reprocessing of nonconforming material. QAD-P-07, rev. 00, 15.11.2018 (rework procedure) Conforming
Does the reprocessing procedure describe product characteristics that allow or not allow Rework criteria defined in procedure ( QAD-P-11)
Conforming
reprocessing? Rv.02 date:-21.07.2021
Did the quality manager or manager’s designee authorize the rework and determine the Yes - Rework of Customer Returns are authorized by
Conforming
reprocessing procedure? Quality Head
Through rework material tracking card in pink

How do you identify that material has been reprocessed? colour. Conforming
Do the records clearly indicate when and how any material has been reprocessed including Verify tracking card of rework material, all the
the quality manager’s authorization of release? information was evident for same. Conforming
Provide evidence that the rework complies with your customer's specifications and / or After rework, parts are being checked against
requirements. inspection standard based on customer specification Conforming
Comments: Ok

1.13 The Quality Department shall review, address, and document customer and internal concerns.
The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the
organization.
Conforming
NA
Yes procedure available

Describe the procedure for reviewing and addressing external customer and internal Procedure for NC Products control QAD-P-07
concerns. Procedure of Customer Complaints QAD-P-12, Rev. Conforming
02,29.01.2022.
Describe the problem solving approach that is used. Fish Bone Diagram, Why Why analysis followed Conforming
Describe the communication process used to respond to the originator. Using Mail, Text messages, etc.. Conforming
Replying to Cosmo India - Black Spot in hole area

Provide a recent example of this procedure in use. Issue Conforming
Comments: Ok

1.14 The organization shall have a continual improvement process.
• The continual improvement process shall be designed to achieve improvements in quality and productivity.
• Identified actions shall be prioritized and shall include timing (estimated completion dates).
• The organization shall show evidence of program effectiveness.
Conforming
NA
Describe the continual improvement process used to achieve improvements in quality and Suggestion and Kaizen - Continual improvement
productivity. projects are taken Conforming
Provide a recent example of how actions are identified, prioritized and completion dates Suggestions are reviewed identified for
Conforming
assigned. implementation.
Describe how the organization measures the effectiveness. Reduction of rework%, productivity increased Conforming
Comments: Ok

1.15 There shall be predefined personnel responsible for management of materials in quarantine area.
Only the quality manager or designee may authorize the disposition of material from quarantine status.
Conforming
NA

Control of Non-conforming products procedure

Define the process for release of material from quarantine. Conforming
followed.
List the authorized personnel with job titles. Quality Head Conforming
Decision given by quality head with in 24 hours
Review evidence that only these persons are releasing materials from the quarantine area. Conforming
according to procdure (QAD-P-07).
Comments: OK


1.16 There shall be documented procedures and / or work instructions for all processes and they shall be available to all of the organization’s personnel.
• There shall be procedures or work instructions available to personnel covering their responsibilities.
• These documents shall include instructions for addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product
segregation (See 2.3, 2.8), product inspection, and general operating procedures.
Conforming
NA
Work instruction available for process startup.

Review the procedure / work instruction for process start-up and shut-down. Conforming
F32(PRD- P-01)
Review the procedure / work instruction for process control during operation. Guidelines available for control the process. Conforming
Work InstructionWI 01(QAD-P-10) was evident for
What is the procedure in place to address potential emergencies?
handling of Abnormal Situations and abnormalities is Conforming
(Such as power outage and / or equipment failure).
handling according to work instruction
Review the procedures for inspection of the product, in process or after completion. Inspection plan followed Conforming
Verify that these procedures / work instructions are accessible to personnel performing the
Available in respective areas Conforming
job at all times.
Comments: OK

1.17 The organization and management shall provide employee training.
• The organization shall provide employee training for all operations.

• All employees, including backup and temporary employees, shall be trained.
• Documented evidence shall be maintained showing the employees trained and the evidence shall include an employee assessment.
• Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.
Conforming
NA
Review the process for initial training of all employees, including backup and temporary. Training procedure followed Conforming
Review the process for ongoing and / or follow-up training. Training plan followed Conforming
Provide a recent copy of the training matrix. Trainings records available Conforming
Provide documented evidence that shows how the organization verifies effectiveness of
training. Training effectiveness monitoring sheet Conforming
Comments: OK
1.18
Essential management and supervisory functions shall be performed by qualified personnel at all times and a matrix of these essential responsibilities shall be
available for review.
• The organization shall maintain a responsibility matrix identifying all essential management and supervisory functions and list the qualified personnel who
may perform such functions.
• It shall identify both primary and secondary (backup) personnel for the essential functions (as defined by the organization).
• This matrix shall be readily available to management at all times.
Conforming
NA
Review and provide an example of the most recent matrix. Departmental activity vs resp. defined Conforming
Confirm that the matrix includes both primary and secondary persons. Yes, Available - Conforming
Describe how and where this information is made available. All respective departments Conforming
Comments: Primary and Secondary Persons to be defined

1.19 There shall be a preventive maintenance program and maintenance data shall be utilized to form a predictive / preventive maintenance program.
• The organization shall have a documented preventive maintenance program for essential process equipment (as identified by the organization).
• The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness.
• Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner.
• Company data, (e.g., downtime, quality rejects, first time-through capability, recurring maintenance work orders, and operator-reported problems) shall be
used to improve the preventive maintenance program.
• Maintenance data shall be collected and analyzed as part of a preventive maintenance program.
Conforming
NA
Show evidence that a documented preventive maintenance program exists. Preventive maintenance plan followed Conforming
Describe the process for reporting problems. Maintenance - problem register implemented Conforming
Verify B/D maint slip, B/D was happened on

01.09.2022 on M/C no. 01 (Oven), due to Convayor
Provide a recent example showing that the person reporting the problem received
sprocket key broken, after close the B/D, Maint. Conforming
feedback after the problem was resolved.
Deptt. Handover the oven to the production after
belt speed verification.

Give a recent example of how the program was used to prevent / predict potential Poka yoke verification, Daily machine checksheet
Conforming
equipment failure. F19(MNT-P-02)
How is the data being generated reviewed with management to improve the quality Major breakdown analysis and implementation of
system? action plan. Conforming
Comments: OK

1.20 The organization shall develop a critical spare part list and the parts must be available to minimize production disruptions.
• Spare part suppliers, minimum quantity and lead times shall be documented.
Conforming
NA
Provide the critical spare parts list. Available, Conforming
Yes, verify WI 06 (MNT-P-02) for spare managemnt
Does the critical spare parts list include inventory, lead time and suppliers? all criteria was defined for same. Conforming
Describe how and when the organization updates the list. On Every 15 Days by physical inventory verification Conforming
What criteria is used to determine whether critical spare parts are kept at the facility or
based on lead time and availability. Conforming
sourced off site.
Describe the process used to maintain minimum quantities. based on the consumption & interchange part Conforming
Comments: ok

CSA SECTION 2 : Floor and Material Handling Responsibility

Section 2 - Floor and Material Handling Responsibility
2.1 The organization shall ensure that customer data entered into the receiving system matches the customer’s shipping documents.
It is critical that all customer requirements and lot identification be correctly transferred to internal documents.
• The facility shall ensure that the data entered in the receiving system match the information on the customer's shipping documents.
• Documented processes and evidence of compliance shall exist (e.g., shop travelers, work orders)
• Sometimes the material received does not precisely correspond to customer shipping documents. The facility shall have a detailed procedure in place to resolve
receiving discrepancies.
• The requirements stated above apply to captive, in-house, commercial and all involved departments.
Conforming
NA
Incoming Material register F02(QAD-P-01)

Describe the receiving process including listing the documentation used. Conforming
Incoming inspection Report F01(QAD-P-01)
Describe the process to identify the coating requirements. Customer PO, Challan, Internal Part No. , Tracking Card Conforming
Describe the reaction process when material received does not correspond to the
Inform to customer, if any mismatch. Conforming
customer’s documents.
Comments: Ok

2.2 Is product clearly identified and stored throughout the surface finishing process and is lot traceability and integrity maintained?
Procedures are required for part and container identification to avoid incorrect processing or mixing of lots.
• As received, in-process, and finished product or material shall be properly segregated, identified, and stored in a dedicated and clearly defined area.
• Out-going lot(s) shall be traceable to the incoming lot(s).
• The discipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.
Conforming
NA
Describe the method that ensures the parts and lot numbers are correctly identified and
Every Trolley contains tracking card F01(QAD-P-05) Conforming
maintained throughout the process.
Verify that received, in-process, and finished product or material is properly segregated, Different trolleys colour & size are used in different
Conforming
identified, and stored in a dedicated and clearly defined area. processes
Comments: Ok

2.3 Procedures shall be adequate to prevent movement of nonconforming product into and out of the production system.
The control of suspect or nonconforming product is necessary to prevent inadvertent shipment or contamination of other lots.
• Procedures shall be adequate to prevent movement of nonconforming product into the production system.
• Procedures shall exist addressing authorized personnel, appropriate disposition, product identification and tracking of material flow in and out of hold area.
• Nonconforming hold area shall be clearly designated to ensure segregation of such material.
Conforming
NA
Holding area is placed inside of the plant with lock and
Where is the nonconforming holding area, and how is it identified? Conforming
key system and identified with display board.
Quality Head is authorised for movement of non-
Describe the procedure to prevent the unauthorized movement of nonconforming products. Conforming
confirming product.
Hold material list is displayed in holding area with in
Provide evidence that material movement in and out of this area is documented. Conforming
and out status.
Comments: Ok
2.4 For bulk processing there shall be a procedure to identify trap points throughout the entire process to reduce risk of unfinished, improperly coated and mixed parts.
• The organization shall have documented procedures to identify and monitor all trap points for each process / equipment.
• Monitoring of potential trap points shall occur at minimum every part changeover.
• Trap points may include: Baskets, barrels, bins, part containers, loading and unloading equipment, oven belts, load hoppers and transfer belts.
Conforming
NA
Describe the procedure to identify and monitor all trap points for each process and / or Trap points is identified visually, where part is trapped.
Conforming
equipment. Trap point is monitored daily shift.
Provide the list of trap points. Trap point list is available Conforming
Comments: ok


2.5 The handling, storage and packaging shall be adequate to ensure product quality is maintained throughout the entire process.
• Handling, storage, and packaging shall be adequate to ensure product quality.

• Part cleanliness shall be maintained throughout the process.
• All parts shall be stored in a controlled environment.
Conforming
NA
Which process steps have dedicated in-process containers? Degreasing, shot blasting and coating Conforming
How are containers maintained to preserve part cleanliness? Covered container is used is after shot blasting process. Confirming
Describe how the containers are inspected to ensure they are free of foreign material. Before using container, it is cleaned. Confirming
What is used for liner material of customer containers before packing finished goods for
shipment? Polythene sheet is being used Confirming
(Materials like newspapers, used cardboard and bags should be avoided).
Provide a list of dedicated storage areas that avoid exposure to contamination and
FG Storage area is located away from the shot blasting
corrosion. (Storage outdoors, near media blasting and corrosive processes such as acid Confirming
shop and it is under the factory shed.
tanks should be avoided).
Comments: Ok

2.6 Each process step shall be documented and traceable.
How does the operator verify that all process steps have been completed in specified order and in within specified time limits?
Conforming
NA
Do you have a document (e.g., shop travelers, job sheet, etc.) that specifies all the processes
Tracking card F01(QAD-P-05) Conforming
for each part number / part family?
Define the procedure that ensures that all processes have been completed in the specified All process steps are defined in the material tracking
Conforming
order. card.
Describe how time sensitive processes are completed in the specified time limits (e.g., wet
NA NA
part transfer).
Provide documentation that this process has been followed. NA NA
Comments: Ok

2.7 Part loading shall be specified, documented and controlled.
• Loading parameters shall be specified, documented and controlled.
• Examples include: parts per rack, part position and orientation, weight per barrel / basket or masking.
Conforming
NA
Describe how the loading parameters are communicated to the operator. Tracking Card/ Loading Guidelines Conforming
Identify how the loading weight or rack quantity is recorded for each load or rack. Data is entered in log book in each process Conforming
Comments: Ok

2.8 There shall be a procedure for material handling, containment action and product segregation in the event of an unplanned process interruption.
Unplanned downtime greatly increases the risk of improper processing.

• Work instructions specifically addressing potential types of unplanned process interruptions shall be accessible to operators.
• Specific instructions shall address containment / reaction plans for each step of the process. Where processes are time critical, immediate actions are required.
Examples include process steps exposing parts to: acidic solutions, current, bake or curing processes.
• Evidence shall exist showing disposition and traceability of affected product.
Conforming
NA
4M Change Management, Procedure QAD-P-08,
What procedure is used to address each step of the process? Conforming
Rev.03 , 15/02/2023
Provide all work instructions that address unplanned process interruptions. Process wise Guidelines available for unplanned process Conforming
How is the affected product traced, dispositioned and documented? 4M Lot number Conforming
Comments: Ok

2.9 Plant cleanliness, environment, and working conditions shall be conducive to ensure product quality.
• Plant cleanliness, housekeeping, environmental, and working conditions shall be adequate to preserve product quality.
• A housekeeping policy shall be clearly defined and executed.
Conforming
NA
Provide a copy of the housekeeping procedure.
Provide a copy of the procedure used to handle dropped or spilled parts. Process for non-confirming and suspected products Conforming
Describe what is done with loose parts found on the floor of the plant. Process for non-confirming and suspected products Conforming

Define the process used to review the facility for conditions that are detrimental to quality
5S Audit Checksheet Conforming
processing such as chemical spills and inadequate ventilation.
Comments: Ok
2.10 Plant lighting shall be adequate in all inspection areas.
Lighting in the part and / or process inspection areas must be adequate for the intended operation.
Conforming
NA
How do you ensure the lighting in the part and / or process inspection areas, including
Monitoring of Lux level Conforming
loading and unloading areas, is adequate for the intended operation?
For part inspection, how do you arrange the lighting to avoid spot lighting, glare, shadows
Light with refractor installed in inspection table Conforming
and distracting reflections?
Comments: ok

CSA SECTION 4 - JOB AUDIT
Section 4 - Coating System Assessment Job Audit - Finished Product Review
Job Identity:
Customer: OCAP Chassis Parts Pvt Ltd
Shop Order Number:
Part Number: 2171691/020
Part Description: Balll Pin Threaded ( M12*1.5)
Material Substrate:
Plating Requirements: Geomet 720
Specification Number and Revision:

Identify Relevant Documents and Actual Conforming
Question
Inspection Element Condition (Provide Data or Values and Embed or Nonconforming
Number
Attach Documents) NA
Attach evidence that the documentation for the

specific part conforms to the requirements including:
4.1 • Advanced quality planning process Available Conforming
• FMEA
• Process Control Plan
What customer specifications or requirements are

4.2 used for this part? Customer requirement is evident. Conforming
• List the specification(s) and revision(s)
4.3 Provide evidence of receiving inspection. Incoming inspection Report found OK Conforming
Provide the job traveler or attach a copy of this • Customer name -

traveler showing: • Lot number -
• Customer name • Weight / quantity -
4.4 • Lot number • Process instructions - Available Backside of the Conforming
• Weight / quantity tracking card
• Process instructions • Inspection requirements - Available Backside of
• Inspection requirements the tracking Card.
If the lot is divided how is the traceability maintained

4.5 throughout the process? Material Lot No. M230309-08 Conforming
Describe the method used to document each

operation as being completed. Is there a sign-off with
4.6 Bar code and scan in each process. Conforming
time stamp, bar code or scan, etc., after each
operation?
Attach work instructions applicable to this part

Basket is identified based on the coating
indicating proper barrel / basket mesh size or
chemical.
4.7 perforation (hole size), load size, appropriate rack Conforming
Basket size mentioned Master list of Jigs and
configuration, appropriate part orientation on rack,
fixture .
etc.
Identify each process table pertaining to this job

audit. Populate the applicable process tables with
4.8 the actual process results / conditions at the time table A Conforming
this part was processed (Columns H and I in Process
Tables A through H).
Were appropriate process steps on the job

Operator manaul sign off the tracking card after
4.9 router / traveler signed off? For electronic systems, a Conforming
completion of process.
screen print is acceptable.
Were all inspection steps, as documented in the

4.10 Yes, this is available In control plan Conforming
control plan performed?
Were steps / operations performed that were not All Operations involve in coating process are
4.11 documented in the control plan? mentioned in control plan. Conforming
If additional steps were performed, were they

4.12 authorized? Through deviation Authorization Conforming
If the order was certified, did the certification

4.13 Tracking Card Conforming
accurately reflect the process performed?

Was the certification signed by an authorized

4.14 individual? Yes, Conforming
Are the parts and containers free of foreign objects

4.15 Yes, Conforming
or contamination?
4.16 Are packaging requirements identified? Packaging requirements are idenfied Conforming
Are parts packaged to prevent mixing or damage to Material packed seprately in polybag /Wooden
4.17 Conforming
parts (parts packed over height of container)? container
Are storage condition sufficient to maintain part

4.18 quality. (e.g., parts are stored indoors in a clean, dry Material are stored in covered shed, dry place Conforming
environment).
Were the parts properly identified and / or labeled

4.19 Yes, Material tag is being used Conforming
before shipping?
Each part may have one or more requirements determined by the

For the finished part, list each test and inspection
4.20 coating specification. Parts must meet each requirement. Add
requirement per customer specification.
additional sections as needed.
Conforming
Below is an example of how to fill out sections in
Inspection Requirements Nonconforming
4.20.x
NA
Test Description: Corrosion Resistance Conforming
Test Method: ISO 9227 Conforming
Example Test frequency or quantity: As per plan Conforming

only
Test Requirement: 720 hrs. no red rust. Conforming
Result:
Attach evidence: - Conforming
Insert audit data below this line. Add additional sections as needed
Test Description: Corrosion Resistance Conforming
Test Method: ISO 9227 Conforming
4.20.1 Test frequency or quantity: As per plan Conforming
Test Requirement: 720 Hours - No Red Rust Conforming
Result:
Attach evidence: Not Done Conforming
Test Description: Coating thickness Conforming
Test Method: XRF Conforming
4.20.2 Test frequency or quantity: Every Lot Conforming
Test Requirement: > 5 micron Conforming
Result:
Attach evidence: 7-15micron Conforming

PROCESS TABLE A - Pretreatment (Aqueous)
All requirements given below are subordinate to applicnler customer / OEM specific requirements
The customer may have additional requirements, e.g., inspection testing or greater frequencies. When performing the job audit the auditor
If minimum requirements are not met, provide supporting records to justify actual conditions. To justify reduced monitoring frequencies, a minimum of 30 consecutive measurements (data points) at stated frequencies
must be documented
If any data points at reduced monitoring frequencies are outside of control limits, then revert back to the frequencies stated under the minimum requirements
Column H and I are used for the Job Audit (Section 4)

Regularly scheduled measurements (e.g., temperature, concentrations, pH) are to be entered in the appropriate row
For section that are not applicable mark NA in the comments column
Instruction for creating the table with the form builder:
Using the Populate Forms lists to the right, select the box that represents the first step of the process flow
Then select the Populate Forms banner and that section of the process table will be added below
For each additional step of the process flow, continue adding sections to the form by selecting the applicable step from the list to the right, followed by selecting the Populate Forms banner.
Fitness between process steps are to be included.
If using multiple counter flowed rinses only insert one Rinse section, document only the condition of the last rinse tank in the series.
Process Line Identification

Type of Line : Rack or Barrel
Observations /
Category / Process Steps Type of Control Monitoring Frequency Job Audit Measurement
Comments
Actual
Conforming
Minimum Actual Actual Measurements
Item # Monitoring Requirement Nonconforming Range
Requirement Condition Condition supporting time
NA
of Job Audit
1.0 Aqueous Cleaning Process (Alkaline or Acid)
There shall be an incoming part assessment procedure with

A1.1 Per Control Plan Yes Once per lot and per part change Every lot Conforming - -
criteria
Automatic Line : Confirm set-up at the

start of production and every process
change. Manually verify every 3
months or after programming change
A1.2 Time Automatic / Manual Automatic PLC Controlled Conforming PLC Controlled PLC Controlled
of equipment maintenance.
Manual Line : Continuously monitor

time in each stage of process
2.0 Cleaning / Descaling Solution
Pressure for spray rinse.

A2.1 Automatic / Manual NA Once every 8 hours NA NA NA NA
Agitation for immersion tanks
Solution Temperature is monitored and controlled if required Continuous monitoring by controller.
A2.2 Automatic Automatic Every lot Conforming 60 - 80 Deg. C 71 Deg. C
by chemical supplier's technical data sheet Manually verify daily
Automatic Max. SAT Every lot

Continuous monitoring by controller.
A2.3 Temperature (Thermocouple) difference allowed ± Automatic recorded in Conforming 60 - 80 Deg. C 71 Deg. C
Manually verify daily
5ºC (10ºF) HMI
Chemical Concentration (Alkaline Cleaner) (if used)

Per chemical supplier recommendation such as:
PH - <9
- free alkalinity PH - 8.0
Every Shift Concentration
A2.4 - total alkalinity Automatic / Manual Manual Once every 8 hours Conforming Concentration -
(8Hours) - 80 - 110
- pH 101.05 gm/Ltr.
Gram/Ltr.
- conductivity
- percentage of cleaner (weight/volume or volume/volume)
Chemical Concentration (Acid Cleaner) (if used) Per chemical

supplier recommendation such as
A2.5 Automatic / Manual NA Once every 8 hours NA NA NA NA
- free acidity or concentration
- metal contamination
Impurity Content
Per chemical supplier recommendation such as
A2.6 - acid spit (oil contamination) Manual NA Once every 8 hours NA NA NA NA
- alkalinity ratio
- iron content
Level Sensor
Indicator and
A2.7 Solution Level Manual Automatic Once every 8 hours Conforming NA NA
automatic
topup
Solution and tank clean out schedule is documented and As per Cleaning
A2.8 followed Manual Manual Per preventive maintenance program and Maint. Conforming NA NA
- Desludging, coalesce, new make-up frequency, etc. Plan
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing or greater frequencies. When performing the job audit, the audit shall verify coater is conforming to customer requirements.

Regularly scheduled measurements (e.g., temperature, concentrations, pH) are to be entered in the appropriate row.
For sections that are not applicable mark NA in the Comments column
*If minimum requirements are not met, provide supporting records to justify actual conditions.
To justify reduced monitoring frequencies, a minimum of 30 consecutive measurements (data points) at stated frequencies must be documented
If any data points at reduced monitoring frequencies are outside of control limits, then revert back to the frequencies stated under the minimum requirements.

Process Line Identification
Type of Line : Rack or Barrel

Observations /
Comments
Actual
Conforming
Minimum Actual Actual Measurements
Item # Monitoring Requirement Nonconforming Range
Requirement Condition Condition supporting time
NA
of Job Audit
3.0 Rinse
Rinse Type - Identify in comment section e.g., Flowing, Automatic
A3.1 Automatic Once every 8 hours done Confirming Continuous Continuous
Counter flowing, Spray, Stagnant, Drag-in / out Flowing
Water Type - Identify in comment section e.g., Municipal.
A3.2 NA NA Municipal.
Deionized (Dl) Reverse Osmosis (RO)
Agitation Type - Identify in comment section, if applicable,
A3.3 Automatic NA Air
e.g., Mechanical (Describe) Air, Ultrasonic.
A3.4 Automatic NA NA NA
Automatic Max. SAT
A3.5 Temperature (Thermocouple), if applicable difference allowed ± NA NA Na
5ºC (10ºF)
A3.6 pH, if applicable Manual Manual Once every 8 hours * done Confirming
A3.7 Conductivity, if applicable Manual NA Once every 8 hours * NA
A3.8 Concentration, if applicable Manual NA Once every 8 hours * NA
A3.9 Flow rate, if applicable Manual NA Once every 8 hours * NA
A3.10 Spray nozzle condition, if applicable Manual NA Once every 8 hours * NA
Verify position of incoming water feed is near the bottom (if
A3.11 Manual Manual Per preventive maintenance program done Confirming
immersion tank)
A3.12 Tank maintenance schedule documented and followed Manual Yes Per preventive maintenance program P.M Confirming
4.0 Acid / Neutral Picking
A4.1 Concentration Manual NA Once every 8 hours * NA
A4.2 Concentration of Fe, per chemical supplier Manual NA Once per day NA
A4.3 Automatic NA NA
Automatic Max. SAT
A4.4 Temperature (Thermocouple), if applicable difference allowed ± NA NA
5ºC (10ºF)
A4.5 Inhibitor (if used) Manual NA Per supplier data sheet NA
A4.6 Solution Level Manual NA Once every 8 hours NA
Solution and tank clean out schedule is documented and
A4.7 followed Manual NA Per preventive maintenance program NA
- Desludging, coalesce, new make-up frequency, etc.
A4.8 Rinse - See Section 3.0 NA

5.0 Aluminum Etching

A5.1 Concentration Manual NA Once every 8 hours NA
A5.2 Concentrations of Al. per chemical supplier Manual NA Once per day NA
Automatic Max. SAT
5ºC (10ºF)

A5.6 Rinse - See Section 3.0 NA NA
6.0 Aluminum Deoxidizing
A6.2 Concentrations of Al. per chemical supplier Manual NA Once per day NA
Automatic Max. SAT
5ºC (10ºF)
7.0 Sealing Rinse (if applicable)

Automatic Max. SAT

5ºC (10ºF)
A7.4 pH, if applicable Manual NA Once every 8 hours NA
A7.5 Solution Level Manual NA Once every 8 hours NA
- Dislodging, coalesce, new make-up frequency, etc.

8.0 Oil / Wax (if applicable)

A8.1 Pressure / Agitation Automatic NA Once every 8 hours NA
Chemical Analysis :
Per chemical supplier recommendation such as
if not used at 100% concentration,
- Concentration
A8.2 Manual NA every 8 hours. If used at 100% NA
- Emulsion Stability
concentration, every lot change.
- Viscosity
- Total Dissolved Solids (TDS)

Automatic Max. SAT
5ºC (10ºF)

9.0 Dry-Off (if applicable)
A9.1 Air temperature is monitored and controlled Automatic Automatic Once every 8 hours Every Lot Conforming 120 - 160 Deg. 140 Deg. C
No zirblast
There is a procedure to ensure dryness of parts prior to Every change of lot number and each No zirblast
A9.2 Visual Visual Each Lot Conforming powder
subsequent coating container powder Sticked
Sticked
10.0 Process Equipment
Process equipment shall be verified and calibrated per Process Table K

Calibration shall be certified, posted and up to date
A10.1
A system shall be used to track calibration dates of equipment
Complete the audit for these identified elements in Process Table K
Guidance Objective Evidence / Comments Conforming Nonconforming NA
What internal system is used for conducting and managing calibration of all relevant equipment identified in
Calibration plan of Measuring Instruments Available Conforming
Process Table K?
Provide the document that lists all relevant equipment identified in Process Table K Master list of Measuring Instruments Available Conforming
How do you ensure calibrations are up to date ? Review Calibration plan V/s Actual Conforming
How do you ensure new equipment has been added to the calibration list and inactive equipment has been
Review of Calibration plan and master list in every month. Conforming
removed ?
Are calibration labels present and up to date for listed equipment ? Calibration stickers are available in Calibrated Instruments Conforming
Sent the faulty instrument to calibration lab to re-calibrate. Reaction plan

What is the reaction plan to any failed verification ? Conforming
is defined

A10.2 Barrels, baskets, process tanks, belts / conveyors, racks, fixtures and drive mechanisms shall be maintained
How do you inspect for the integrity of the barrels, baskets, process tanks, racks, contact points, belts /
conveyors and drive mechanism? Check Daily as per Daily Machine check sheet.
Conforming
(e.g., wear, perforations, trap points, plugged holes, door gaps, other damage) As per PM check sheet on schedule.
Where are the inspection results documented ?
What is your preventive maintenance program for barrels, baskets, racks, contact points, process tanks and Preventive Maintenance plan available for production machine &
Conforming
drive mechanism ? Supporting Equipments.

What is the maintenance program for mechanical / chemical cleaning of barrels, baskets, racks, contact points
Basket/Tray/Tank/trolley Cleaning is done as per decided frequency. Conforming
and process tanks ?
How is each basket, barrel or rack uniquely identified for tracking purpose ? Not Applicable -
All filtration shall be maintained

A10.3
The organization shall have a preventive maintenance system that is documented and implemented
What is the preventive maintenance program for filters ? NA
How is the filter type identified during use ? NA
If reusable filters are used, do they meet the supplier's recommendations ? NA
If disposable filters are used, do they meet the supplier's recommendations ? NA
What are your criteria for filter replacement and / or cleaning ? NA
What information is used to determine the required mesh size ? NA
How is compatibility with the process determined ? NA
Describe the preventive maintenance program for all solution filters to include plate, filter bag and cartridge NA
Describe the preventive maintenance program for all air filters used on ovens, dryers, chillers, blowers and
Preventive Maintenance plan available for all Supporting Equipments. Conforming
fans etc.
All process and equipment alarms shall be used tested on a quarterly basis at a minimum
A10.4
The organization shall have a preventive maintenance system that is documented and implemented

What is the preventive maintenance program where alarms are used for solution temperature, level control,
All poka yoke verification is being done on shift wise Conforming
environmental control, faults, etc. ?
What are the alarms that are tested and their test frequency ? All poka yoke verification is being done on shift wise Conforming
A10.5 Processing equipment is designed / optimized for "soft handing" of parts
Are chutes lined to prevent part damage ? Lined with Teflon sheet Conforming
Inclined Teflon sheet is used while collecting the material from the belt to
What technique(s) are used to minimize drop heights ? Conforming
trolley to provent part damage
A10.6 Part transfer equipment is maintained
What is you program to assure cleanliness of belts, conveyors, chutes, vibratory tables, etc. ? Daily 5S activity is being done Conforming
What is your maintenance program for belts, conveyors, chutes, vibratory tables, etc. ? As per PM Plan. Include in Machine Preventive Maintenance Check sheet Conforming
A10.7 In-process and customer containers are managed and maintained
How do you identify and segregate in-process containers for different processes ? The design of trolley and handle colour is different Conforming
What is your maintenance program for keeping in-process containers clean and in good condition ? As per monthly plan, Daily 5S activity is being done Conforming
How to you ensure that the customer containers do not degrade the quality of the coated parts ? Before keeping the finished product in customer container, cleaning of
Conforming
(e.g., customer container may arrive damaged, oily, dirty) container is being done
Electrical system shall be maintained
A10.8
Coater shall have a preventive maintenance system that is documented and implemented
Describe the preventive maintenance program for rectifiers (e.g., voltage and amperage) NA
All anodes / cathodes, contacts and bussing shall be maintained.

NA
Coater shall have a preventive maintenance system that is document and implemented
Describe the preventive maintenance program including cleanliness, electrical resistance and electrical shorts. NA


11.0 Test Equipment (Process Control and Finished Part Quantity)
Test Equipment shall be verified and calibrated as per Process Table K

Calibrations shall be certified, posted and up to date.
A11.1
Wet Analysis
Lab testing chemicals is use after verification of Expiry date or shelf life. Conforming
Before use, chemicals must be checked for shelf life and / or expiration date
Daily Verification of PH meter is being done with standard ph solution and
pH Meter Conforming
Calibration Annually by outside lab.
Daily Verification of PH meter is being done with ph solution and
pH Probes (must be solution compatible) Conforming
Calibration Annually
Laboratory Balance (Weight Scale) Not Applicable
Rectifier Not Applicable
Hand Held Thermometer Not Applicable
Temperature Controller Daily verification and Calibration Every Six months Conforming
Thermocouple calibration done Conforming
Solution Mixer Not Applicable

Amp Meter / Volt Meter Not Applicable
Filters Not Applicable
Conductivity Meter Not Applicable
Conductivity Probes (must be solution compatible) Not Applicable
Ultrasonic Cleaner, if applicable Not Applicable

Proceed to PT B, PT C or PT H

PROCESS TABLE B - Pretreatment (Mechanical)
All requirements given below are subordinate to customer specific requirements
The customer may have additional requirements, e.g., inspection testing or greater frequencies. When performing the job audit the auditor shall verify coater is conforming to customer requirements

For multiple tanks that serve the same purpose copy and paste sections as needed
Observations /
Category / Process Steps Type of Control Monitoring Frequency Comments Job Audit Measurement
Actual
Conforming
Minimum Actual Measurements
Item # Monitoring Requirement Actual Condition Nonconforming Range
Requirement Condition supporting time
NA
of Job Audit
1.0 Abrasive Blast Process
For batch operations per load. For No oil and

No oil and grease
B1.2 Parts shall be clean and free of oil and grease Manual Manual integrated operations once every 8 Every Lot Conforming grease after
after degreasing
hours degreasing
Automatic in
B1.3 Load Weight is verified Manual / Automatic Degressing Per load Every Lot / Per Load Conforming
Supplier TC & Grade verification

B1.4 Media Size / type is appropriate for the part being processed Manual Manual Per part number during incoming inspection Conforming Supplier TC Supplier TC
B1.5 Dwell time is clearly defined Manual / Automatic Automatic Per load Per Load Conforming - -
Verify blazing force / energy is sent and maintained with
B1.6 control limits, e.g., Amperage Draw, PSI Manual / Automatic Automatic Per load Per Load Conforming - -
B1.7 Verify abrasive media volume is sufficient Manual Manual Once every 8 hours Per Load Conforming - -
As per acceptance
B1.8 Verify dust collector efficiency / air flow is within limits Manual Automatic Once every 8 hours Every Lot Conforming Dust Level
Criteria - OK
Media size / life

Continuous Sucking system
B1.9 Media size is being checked on a regular schedule to Manual / Automatic Automatic Once per week Conforming - -
working
determine effective cleaning and life for product mix
Part cleanliness is checked after process. Surface cleanliness

No black spots
B1.10 check must be conducted using a chemical e.g., copper Manual Manual Once every 4 hours Every Lot Conforming No black spots observed
sulfate, surface tension ink or other qualitative method
If additional blazing is required, management approval is

B1.11 needed Manual / Automatic Automatic Per load Every Lot / Per Load Conforming - -
B1.12 Surface profile is checked after process, if applicable Manual NA Per load NA
Process equipment shall be verified and calibrated pler Process Table K

Calibrations shall be used to track calibration dates of equipment
B2.1 A system shall be used to track calibration dates of equipment's

Process Table K ? HMI Installed - PLC Controlled Conforming
Provide the document that lists all relevant equipment identified in Process Table K Not Applicable
How do you ensure calibration are up to date ? Not Applicable

removed ? Not Applicable
Are calibration labels present and up to date for listed equipment ? Not Applicable
What is the reaction plan to any failed verification ? Not Applicable
B2.2 Barrels, belts / conveyors, racks, fixtures and drive mechanisms shall be maintained
How do you inspect for the integrity of the barrels, racks, belts / conveyors and drive mechanisms ? e.g., wear, Check Daily as per Daily Machine check sheet.
perforations, trap points, plugged holes, door gaps, other damage) As per PM check sheet on schedule. Conforming
Preventive Maintenance plan available for production machine & Supporting Equipments.
What is the maintenance program for attels, belts / conveyors, racks fixtures and drive mechanisms ? Conforming
How is each barrel or rack uniquely identified for tracking purposes ? NA
All filtration equipment shall be maintained

B2.3 The organization shall have a preventive maintenance system that is documented and implemented


What is the preventive maintenance program for filters ? NA
How is the filter type identified during use ? NA
Describe the preventive maintenance program for all filters used on ovens, dryers, chillers, blowers and fans,
etc. NA
How is the dust collection system maintained ? (e.g., pressure differential gages / sensors) Dust collection (Cartridge Filter) is cleaned everyday Conforming
All process and equipment alarms shall be tested on a quarterly basis at a minimum
B2.4 The organization shall have a preventive maintenance system that is documented and implemented
What is the preventive maintenance program where alarms are used for environmental control, faults, etc. ? All poka yoke verification is being done on daily basis. Conforming
What alarms are tested and define the test frequency ? All poka yoke verification is being done on daily basis. Conforming

B2.5 Processing equipment is designed / optimized for "soft handling" of parts
Are chutes lined to prevent part damage ? Lined with rubber sheet Conforming
What technique(s) are used to minimize drop heights ? Inclined Teflon sheet is used while collecting the material from the belt to trolley Conforming
B2.6 Part transfer equipment is maintained
What is you program to assure cleanliness of belts, conveyors, chutes, vibratory labels, etc. ? Daily 5S activity is being done Conforming
What is your maintenance program for belts, conveyors, chutes, vibratory tables, etc. ? As per PM Plan, Include in Machine Preventive Maintenance Check sheet Conforming
B2.7 In-process and customer containers are managed and maintained
How to you ensure that the customer containers do not degrade the quality of the coated parts ? (e.g.,
customer container may arrive damaged, oily, dirty) Before keeping the finished product in customer container, cleaning of container is being done Conforming
B2.8 The blasting force / energy supply system shall be maintained (e.g., Amperage Draw, PSI)
Describe the preventive maintenance program for drive motors (e.g., voltage and amperage) As PM Plan, Included in Machine PM Check sheet Conforming


B3.1

Wet Analysis
Before use, chemicals must be checked for shelf life and / or expiration date Not Applicable
Media flow rate - amp meter Not Applicable
Part dust residue test capacity Dust level is checked on every lot Confirming
Surface profile assessment capability, if applicable Not Applicable
Media fine removal capacity Not Applicable
Media size distribution capacity - sleeves / lab balance, laser Not Applicable
Media pattern assessment capability Once in day verification done Confirming
Part dryness ceramic test media (e.g., Zirblast), if possible Not Applicable
Part cleanliness assessment - Copper surface solution for Hogaboom test surface tension ink, if applicable Not Applicable
Phenolpthalein solution for alkaline contamination check, if applicable Not Applicable
Laboratory Balance (Weight Scale) Not Applicable

Proceed to PT A, PT C or PT G

PROCESS TABLE E - Spray Coating
For a spray zinc-flake, see Process Table G.

Observations /
Comments
Actual
Conforming
Minimum Measurements
Item # Actual Condition Monitoring Requirement Actual Condition Nonconforming Range
Requirement supporting time
NA
of Job Audit
1.0 Part Appearance
Pretreated parts are inspected for cleanliness and / or uniform

conversion coating or paint layer (when applicable)
For parts that are anodized prior to paint, time interval

between anodizing and paint shall be documented and less
AT start of production cycle
E1.1 than 24 hours. No chemical sealers shall be used. Manual Not Applicable Not Applicable
and each container of parts
For plastic substrates, appropriate adhesion promoter or
alternative surface preparation have been verified
This must be performed between each coating layer.
Mutilation prevention items (e.g., gloves, belt buckle covers,

E1.2 Manual Not Applicable Ongoing
watch covers) are in place
Paint racks and / or fixtures are visually inspected for Periodic
E1.3 Manual Manual Ongoing Conforming
cleanliness, excessive paint build-up, bent hooks, etc. Verification
There is a paint rack / fixture maintenance program. Program Per preventative maintenance
E1.4 Manual Manual As per PM Plan Conforming
must define rack / fixture cleaning intervals. schedule
E1.5 Surface tension is within specifications, if applicable Manual Not Applicable Once every 4 hours
2.0 Paint Mixing
Paint mixing rooms are controlled (mixing tank, grounding, During Every
E2.1 closed container, properly enclosed space, temperature, clean Automatic / Manual Actual Condition Once every 8 hours Chemical Conforming
environment) Preparation
There is a stock rotation system (FIFO) in place and being

E2.2 Manual Manual Ongoing Ongoing Conforming
utilized to ensure that older material is used first
Paint agitation / time and reduction (solvent package)

E2.3 procedures follow the chemical manufacturer technical data Manual Manual Ongoing Ongoing Conforming
sheet
Appropriate mixing equipment is used, capable of dispersing

settled solids. The blade type, shaft length, and power rating Chemical supplier
E2.4 Yes Ongoing Ongoing Conforming
shall be consistent with the chemical manufacturer approved equipment
recommendations
Prior to start of production

and every process change
Viscosity is verified to be within operational limits and and / or addition
E2.5 Manual Manual Once in 4 hours Conforming
documented
For continuous operations
check once every 8 hours

Solids content is verified to be within operational limits and and / or addition
E2.6 Manual Manual done Conforming
documented
Solvent / deionized water additions for viscosity / solids Chemical supplier

E2.7 Yes Ongoing Ongoing Conforming
adjustment shall be documented approved equipment

Paint temperature is verified to be within operational limits and / or addition
E2.8 Automatic / Manual Manual Every 4 hours Conforming
and documented
Automatic Max. SAT Continuous monitoring by

E2.9 Temperature (Thermocouple) difference allowed ± Manual controller. Manually verify continious Conforming
5ºC (10ºF) daily
At installation and
The coating filter size and type follow chemical manufacturer
E2.10 Manual Manual replacement of filters per Before use
recommendations
maintenance schedule


Prior to start of production,

Pump pressures are set and pressure readings are verified and
E2.11 Manual Manual every process change and Every Lot Conforming
documented to be within operational limits
once every 8 hours.
Circulation (flow meter, pressure gage) is monitored and
E2.12 Automatic / Manual Manual every process change and Every 4 hours Conforming
documented
once every 8 hours.
Filters are in use (not by-passed) and pressures monitored. Prior to start of production,
E2.13 Filers are changed before pressure differential exceeds 10 PSI Automatic / Manual Not Applicable every process change and - -
(70 kPs) once every 8 hours.
3.0 Primer / Promoter

E3.1 Destatioizing air is operational (Plastic parts only) Automatic Not Applicable every process change and
once every 8 hours.
E3.2 Booth balance (air flow is monitored and documented Automatic / Manual every process change and
once every 8 hours.
For manual process, prior to

start of production and every
4 hours.
Booth temperature and humidity are monitored and
E3.3 Automatic / Manual
documented, if applicable
For automated process, at the
process change
Atomizer parameters are set within operational limits

- fluid flow
and every process change. For
E3.4 - air pressure (atomizing fan, shaping) Automatic / Manual
continuous operations once
- electrostatics
per day.
- mixing
For manual change, prior to
process change.
E3.5 Application time is verified and documented, if applicable Automatic / Manual
For automated process, verify
once per month, or after every
program change or major
maintenance.

4.0 Basecoat
Flash times between coats are set at chemical manufacturers At the start of production and
E4.1 Not Applicable
recommendations every process change
At the start of production and
E4.2 Thickness of preceding layers is verified, if applicable Manual Every Lot Conforming
every process change

4 hours.
E4.3 Manual Every Lot Conforming
process change

E4.4 Temperature (Thermocouple) difference allowed ± Manual controller. Manually verify Every Lot Conforming
5ºC (10ºF) daily

- fluid flow
Only Air Pressure and every process change. For
E4.5 - air pressure (atomizing fan, shaping) Automatic / Manual Every Lot Conforming
- Automatic continuous operations once
- electrostatics
per day.
- mixing
process change.
E4.6 Application time is verified and documented, if applicable Automatic / Manual Not Applicable
1 per month, or after every
maintenance.
5.0 Basecoat


Oven set points(s) and energy type (Convection/IR/UV,etc) are
E5.1 verified to be within chemical supplier's recommended limits Manual Actual Condition Automatic
and documented
every 8 hours.

and every two hours. With a
E5.2 Oven temperature is monitored and recorded Automatic Automatic temperature control alarm, Every Lot Conforming
frequency may be reduced to
once every 8 hours.

E5.3 Temperature (Thermocouple) difference allowed ± Automatic controller. Manually verify Every Lot Conforming
5ºC (10ºF) daily
For each coating in use, proper cure or drying time parameters

Every three months and after
E5.4 are verified based upon chemical manufacturer technical data Manual Manual Every Month Conforming
oven modification or repair
sheet
Per preventative maintenance
E5.5 Air filter (if used) is replaced Manual Manual As per PM Plan Conforming
schedule
After process change and as
Foil solids content after heated flash meets the chemical
E5.6 Manual Manual recommended by chemical Every lot Conforming
supplier's recommendation
manufacturer

6.0 Clear Coat

Flash times between coats are set at chemical manufacturers At the start of production and
E6.1 Automatic / Manual Not Applicable
recommendations every process change
At the start of production and
E6.2 Thickness of preceding layer(s) is verified, if applicable Manual

4 hours.
E6.3 Automatic / Manual
process change

E6.4 Temperature (Thermocouple) difference allowed ± controller. Manually verify
5ºC (10ºF) daily

- fluid flow
E6.5 - air pressure (atomizing fan, shaping) Automatic / Manual
- electrostatics
per day.
- mixing
process change.
E6.6 Application time is verified and documented, if applicable Automatic / Manual
1 per month, or after every
maintenance.

E7.1
Calibration plan of Measuring Instruments Available Conforming
Process Table K?
Provide the document that lists all relevant equipment identified in Process Table K Master list of Measuring Instruments Available Conforming
Review of Calibration plan and master list in every month. Conforming
removed ?
Sent the faulty instrument to calibration lab to re-calibrate.
What is the reaction plan to any failed verification ? Conforming
Reaction plan is defined


E7.2 Belts / conveyors, racks, fixtures and drive mechanisms shall be maintained
How do you inspect for the integrity of the racks, contact points, belts / conveyors and drive mechanism?
Check Daily as per Daily Machine check sheet.
(e.g., wear, perforations, trap points, plugged holes, door gaps, other damage) Conforming
As per PM check sheet on schedule.
Preventive Maintenance plan available for production machine &

What is your preventative maintenance program for racks, contact points, process tanks and drive mechanism ? Conforming
Supporting Equipments.
What is the maintenance program for mechanical / chemical cleaning of racks and contact points ? Basket Cleaning is done as per decided frequency. Conforming
How is the environmental control maintained in the application area and powder storage area ? (humidity,
Chemical Storage Area - Cold Room Conforming
temperature, air flow, cleanliness, etc.)
How is each rack uniquely identified for tracking purposes ? Not Applicable -
All filtration shall be maintained
E7.3
The organization shall have a preventative maintenance system that is documented and implemented
What is the preventative maintenance program for filters ? Not Applicable

How is the filter type identified during use ? Not Applicable
If reusable filters are used, do they meet the supplier's recommendations ? Not Applicable
If disposable filters are used, do they meet the supplier's recommendations ? Not Applicable
What are your criteria for filter replacement and / or cleaning ? Not Applicable
What information is used to determine the required mesh size ? Not Applicable
How is compatibility with the process determined ? Not Applicable
Describe the preventive maintenance program for all solution filters to include plate, filter bag and cartridge Not Applicable
Describe the preventive maintenance program for all air filters used on ovens, dryers, chillers, blowers and fans
Not Applicable
etc.

All process and equipment alarms shall be tested on a quarterly basis at a minimum
E7.4
What is the preventative maintenance program where alarms are used for paint temperature, level control,
All poka yoke verification is being done on daily basis. Conforming
What are the alarms that are tested and their test frequency ? All poka yoke verification is being done on daily basis. Conforming
E7.5 Process equipment is designed / optimized for "soft handling" of parts
Is chutes lined to prevent part damage ? Lined with Teflon sheet Conforming
Inclined Teflon sheet is used while collecting the material from the Conforming
What technique(s) are used to minimize damage while handling ?
belt to trolley
E7.8 In-process and customer containers are managed and maintained

How do you ensure that the customer containers do not degrade the quality of the coated parts ? (e.g., customer Before keeping the finished product in customer container,
Conforming
container may arrive damaged, oily, dirty) cleaning of container is being done


Electrical system shall be maintained

E7.9
Coater shall have a preventative maintenance system that is documented and implemented
Describe the preventative maintenance program for rectifiers (e.g., voltage and amperage) Not Applicable
All anodes / cathodes, contacts and bussing shall be maintained

Not Applicable
Coater shall have a preventative maintenance system that is documented and implemented
Describe the preventative maintenance program including cleanliness, electrical resistance and electrical shorts Not Applicable

E8.1
pH meter Not Applicable -

pH Probes (must be solution compatible) Not Applicable -
% Solids Testing - Moisture Analyzer or Lab Oven Not Applicable -
Laboratory Balance (Weight Scale) Daily Verification and Calibration Annually Confirming
Viscosity Cup or equivalent Calibration Annually Confirming
Weight per Gallon capability - Cup or Hydrometer Replacement Annually Confirming
Hand Held Thermometer Replacement Annually Confirming
Paint / Solution Mixer Daily Verification Confirming
Booth Temperature / Humidity Controller Daily Verification and Calibration Annually Confirming
Circulation Flow Meter / Pressure Gauge Calibration Annually Confirming
Process Air Cleanliness Control Not Applicable -
Process Air Control - Shaping, Atomization, Fluids Not Applicable -
Thermocouple done Confirming
Amp Meter / Volt Meter Not Applicable -


Conductivity Probes (must be solution compatible) Not Applicable
Wet Analysis Lab testing chemicals is use after verification of Expiry date or shelf
Conforming
Before use, chemicals must be checked for shelf life and / or expiration date life.
Part dryness ceramic test media (e.g., Zirblast), if possible Zirblast Powder Conforming
Blacklight (for UV tracer identification) Not Applicable
Water immersion Bath Testing Not Applicable
Thickness measurement device - Magnetic induction / Eddy current gauge or Microscope for cross sectional
Not Applicable
thickness measurement
Weighing Balance (0 - 420 gram) & XRF Machine (Fischerscope
Coating weight capability (as alternative to film thickness measurement) Conforming
Machine) , Calibration Annually
Salt Spray Cabinet Presto Salt Spray Chamber, Calibration Annually Conforming
Ultrasonic Cleaner Not Applicable
Coefficient of Friction / Torque Tension (required for fasteners) Not Applicable
Adhesion Test Capability - scribe and tape Nichiban Tape Conforming
Cure Test - Solvent rub or hardness, if applicable Not Applicable
Gloss Meter Not Applicable
Color Meter Not Applicable
Light Booth Not Applicable
Proceed to PT 1

PROCESS TABLE G - Dip-Spin and All Zinc-Flake Application Methods
All requirements given below are subordinate to customer / OEM specific requirements

*If minimum requirements are not met, provide supporting records to justify actual conditions. To justify reduced monitoring frequencies, a minimum of 30 consecutive measurements (data points) at stated frequencies must be
documented. If any data points at reduced monitoring frequencies are outside of control limits, then revert back to the frequencies stated under the minimum requirements.
Category / Process Steps Type of Control Monitoring Frequency Observations / Job Audit Measurement
Comments
Actual
Item # Minimum Requirement Actual Monitoring Requirement Actual Conforming Range Measurements
Condition Condition Nonconforming NA supporting time
of Job Audit
1.0 Coating Material Application
G1.1 Pretreatment, coating and post treatment shall be completed All described processes in Yes Ongoing Ongoing Conforming
in the same building the same building
After pretreatment, and immediately before each coating,

G1.2 parts are inspected for flash rust, wetness, cleanliness, Visual Inspection Yes Ongoing Ongoing Conforming
phosphate coating uniformity (when applicable), oil or other
defects
G1.3 Containers used to hold parts between coating operations are Visual Inspection Yes Each container Ongoing Conforming
free from blast media, oil, grease or other contaminants
Parts shall be stored indoors in a staging area that does not

affect the cleanliness and quality of parts. The staging area
G1.4 shall not be adjacent to open doorways or windows exposing Designated staging area. Yes Ongoing Ongoing Conforming
parts to water, dirt, fumes, blast media or other
contaminations.
After pretreatment, parts shall be coated within the time limit

G1.5 Per application manual / Yes Ongoing Ongoing Conforming
specified by the customer specification and / or chemical
customer specification
supplier application manual
2.0 Coating Material
Manual measurement Supplier Test

G2.1 Incoming coating material viscosity and percent solids are Each new lot of coating material Every Batch Conforming
and compare to Certificate
checked per chemical supplier application manual
certification verification
Appropriate mixing equipment shall be used and capable of

G2.2 dispersing settled solids. The blade type, shaft length, and Chemical supplier Yes Ongoing Ongoing Conforming
power rating shall be consistent with chemical supplier's approved equipment
recommendations. Hand mixers are not allowed.
G2.3 Coating material shall be stored per chemical supplier Per chemical supplier Yes Ongoing Ongoing Conforming
requirements. requirements
G2.4 When not in use, coating material is kept covered and / or Per chemical supplier Yes Ongoing Ongoing Conforming
sealed per chemical supplier requirements. requirements
G2.5 Coating material storage area is clean and organized so each Manual Yes Ongoing Ongoing Conforming
coating material is easily found and to prevent contamination.

3.0 Coating Process and Bath
Verify that the coating bath is uniformaly mixed (e.g., no

G3.1 Manual Yes Prior to start of production and before Before start of Conforming
setting or agglomeration checked by viscosity cup and open
any additions. production.
gage
G3.2 Secondary and feed tanks are verified for setting Manual NA Prior to start of production and every NA
agglomeration and viscosity shift.
G3.3 Coating material filtration as required by chemical supplier Manual Yes Per preventative maintenace schedule As per schedule Conforming
guidelines / manual.
G3.4 Coating material temperature Automatic / Manual Manual Prior to start of production and once Every Batch Conforming
every 2 hours *
Automatic Max. SAT Continuous

G3.5 Temperature (Thermocouple) Continuous monitoring by controller.
difference allowed ± 5ºC Automatic Monitoring Conforming
Manually verify daily.
(10ºF) Through HMI.
G3.6 Viscosity as required by chemical supplier guidelines / manual Manual YES Prior to start of production and once Start of Conforming
every 2 hours * production
G3.7 Percent (%) solids by chemical supplier guidelines / manual Manual NA Prior to start of production and before -
G3.8 Volume (coating material depth in process tank) Automatic / Manual Manual Prior to start of production and once Before start of Conforming
every 2 hours * production.

Equipment surfaces in contact with coating (e.g., vibratory

G3.9 Manual Manual Once every 8 hours and before every Every lot Conforming
feed tables) are free of loose debris and excess coating
process change
buildup
Basket shall be undamaged and free from coating buildup.

G3.10 Manual Manual Prior to start of production, every Before start of Conforming
Damaged or dirty baskets shall be removed from service
process change, and every 4 hours. production.
immediately.
G3.11 Coating material and / or viscosity reducing agent additions Manual Manual Each addition Yes Conforming
are verified before production continues.
Viscosity cups are cleaned after each use. The cups shall be
G3.12 stored in a designated location and protected against Manual Manual After each use Yes Conforming
contamination and damage.
4.0 Application Parameters Dip-Spin
G4.1 Loading weight shall be defined for each part and documented Automatic / Manual Automatic Every lot Yes Conforming
in the processing manual, traveler, or process recipe.
G4.2 Baskets are ketp less than 70% full by volume Automatic / Manual Automatic Every lot Yes Conforming
Coating parametrers are controlled and verified via external

G4.3 display (dip time, spin speed, spin time, spin cycle, spin Automatic / Manual Automatic Every lot Yes Conforming
direction and basket tilting)
There is a system (raking, vibe table, etc.) to uniformly

G4.4 Automatic / Manual Manual Every coating load Material spread Conforming
distribute parts prior to curing to ensure proper cure and
seperately.
prevent parts from sticking and minimize touch marks
Inspect prior to start of production, Before start of

G4.5 Equipment and fixtures that are in contact with parts (baskets, Manual Manual Conforming
every proces change and every 4 production -
loading tables, chutes, conveyor belts, etc.) are kept clean
hours. daily
G4.6 There shall be soft handling of parts (shallow drops, lined Automatic / Manual Automatic / Ongoing Yes Conforming
chutes and hoppers, bumper boards, etc.) Manual
Parts are within recommended temperature range per

G4.7 chemical supplier recommendation or application manual Manual Manual Ongoing Yes Conforming
before each coating step.

5.0 Application Parameters Spray
Parts shall be properly racked or fixture to minimize touch

G5.1 marks. Racks and fixtures shall be defined for each part and Manual Not Applicable Every lot
documented in the process manual, traveler, or process
recipe.
G5.2 Parts shall be completely within the spray pattern. Manual Every lot
Coating parameters shall be controlled, verified and
G5.3 documented (e.g., air pressure, voltage, electrostatics, Automatic / Manual Every lot
material flow)
Inspect prior to start of production,
G5.4 Equipment, racks and fixtures that are in contact with parts Manual every proces change and every 4
are kept clean
hours.
Parts are within recommended temperature range per
G5.5 chemical supplier recommendation or application manual Manual Ongoing
before each coating step.
Prior to start of produciton and every 4

G5.6 Booth temperature and humidity are monitored and Automatic / Manual hours. With a control alarm, frequency
may be reduced to once every 8 hours.
G5.7 Conveyor speed is verified and documented Automatic Start of production and every process
change

G6.1 Calibration shall be certified, posted and up to date
Complete the audit for these identifed elements in Process Table K
What internal system is used for conducting and managing calibration of all relevant equipment identified in Calibration plan of Measuring Instruments Available Conforming
Process Table K?
Provide the document that lists all relevant equipment identified in Process Table K Master list of Measuring Instruments Avaialable Conforming
How do you ensure new equipment has been added to the calibration list and inactive equipment has been Review of Calibration plan and master list in every month. Conforming
removed ?
What is the reaction plan to any failed verification ? Sent the faulty instrument to calibration lab to re-calibrate. Conforming
G6.2 Baskets, coating tank, belts / conveyors, racks, fixtures and drive mechanisims shall be maintained
How do you inspect for the integrity of the baskets, coating tank, belts / conveyors and drive mechanisim?
Check Daily as per Daily Machine checksheet. Conforming
(e.g., wear, perforations, trap points, plugged holes, door gaps, other damage)
As per PM checksheet on scheudule.

Preventive Maintenance plan available for production machine & Supporting

What is your preventative maintenance program for baskets, coating tank and drive mechanisim ? Equipments. Conforming
What is the maintenace program for mechnical / chemical cleaning of baskets, and coating tanks ? Basket Cleaning is done as per decided frequency. Conforming
How is each basket and coating tank uniquely identified for tracking purposes ? All basket are identified with Basket No. Conforming

G6.3 Racks and fixtures shall be maintained
How do you inspect for the integrity of the racks and fixgures ?
Check Daily as per Daily Machine checksheet for Baskets Conforming
(e.g., broken electrical contacts, coating build up and other damage)
As per PM checksheet on scheudule.
What is your preventative maintenance program for racks and fixtures ? Preventive Maintenance plan available for production machine & Supporting Conforming
Equipments for Baskets
How is each rack or fixture identified for tracking purpose ? NA
G6.4 All filtration equipment shall be maintained

The organisation shall have a preventative maintenance system that is documented and implemented
What is the preventative maintenance program for filters ? NA

How is the filter type identifed during use ? NA
Describe the preventive maintenance program for all air filters used on ovens, dryers, chillers, blowers and fans etc. Preventive Maintenance plan available for all Supporting Equipments. Conforming

G6.5 Magnets may be used to remove metal fines.

If used, the organisation shall have preventative maintenance system that is documented and implemented
What is the preventative maintenance program for magnets ? NA NA
G6.6 All process and equipment alarms shall be tested on a quarterly basis at a minimum
What is the preventative maintenance program where alarms are used for solution temperature, level control, All poka yoke verification is being done on daily basis. Conforming
What are the alarms that are tested and their test frequency ? All poka yoke verification is being done on daily basis. Conforming
G6.7 Process equipment is designed / optimized for "soft handling" of parts
Are chutes lined to prevent part damage ? Lined with teflon sheet Conforming
What technique(s) are used to minimize drop heights ? Inclined teflon sheet is used while collecting the material from the belt to Conforming
trolley
G6.8 Part transfer equipment is maintained
What is your program to assure cleanliness of belts, conveyors, chutes, vibratory tables, etc ? Daily 5S activity is being done Conforming
What is your maintenance program for belts, conveyors, chutes, vibratory tables, etc ? Inlude in Machine Preventive Maintenance Checksheet Conforming


G6.9 In-process and customer containers are managed and maintained

How do you identify and segregate in-process containers for different processes ? The design of trolley and color is different Conforming
What is your maintenance program for keeping in-process containers clean and in good condition ? Daily 5S activity is being done Conforming
How do you ensure that the customer containers do not degrade the quality of the coated parts ? Before keeping the finished product in customer container, cleaning of Conforming
(e.g., customer container may arrive damaged, oily, dirty) containner is being done

E8.1 Calibrations shall be certified, posted and up to date.
Wet Analysis Lab testinng chemicals is use after verification of Expiry date or shelf life. Conforming
Before use, chemicals must be checked for shelf life and / or expiration date
pH meter Verification of PH meter is being done with ph solution and Calibrated Annually Conforming
pH Probes (must be solution campatible) Verification of PH meter is being done with ph solution and Calibrated Annually Conforming
% Solids Testing - Moisture Analyzer or Lab Oven / Lab Balance Not Applicable
Laboratory Balance (Weight Scale) Verification of Weighing Balance is being done with standard weight Bar and Conforming
Calibrated Annually
Viscosity Cup or equivalent NA
Hand Held Thermometer Verification of Glass thermometer is being done with Master Glass Conforming
Thermometer - Replace Annually
Paint / Solution Mixer Daily Verification
Temperature Controller Daily Verification & Calibration every six months Conforming
Amp Meter / Volt Meter Not Applicable
Filters Not Applicable

Conductivity Probes (must be solution compatible) NA

Lab Oven Controller NA
Thickness measurement device - Magnetic induction / Eddy current gauge or Microscope for cross sectional XRF Machine (Fischerscope Machine) / Microscope for cross sectional Conforming
thickness measurement thickness measurement, Calibration Annually
Salt Spray Cabinet Presto Salt Spray Chamber, Calibration Annually Conforming
Ultrasonic Cleaner, if applicable NA
Coefficient of Friction / Torque Tension (required for fasteners) NA
Scribe and Tape for Adhesion Test Nichiban Tape Conforming
Coating weight capability (as alternative to film thickness measurement) Weighing Balance (0 - 420 gram) & XRF Machine (Fischerscope Machine) , Conforming
Calibration Annually
Part dryness ceramic test media (e.g., Zirblast) Zirblast Powder Conforming
Blacklight (for UV tracer identification) NA
Booth Temperature / Humidity Controller Hygrometer, Calibration Annually Conforming
Process Air Cleanliness Control NA
Process Air Control - Shaping, Atomization, Fluids NA
Cure Test - Solvent rub or hardness, if applicable NA
Proceed to PT 1

PROCESS TABLE I - Cure

Observations /
Comments
Actual
Conforming
Item # Minimum Actual Monitoring Requirement Actual Condition Range Measurements
Nonconforming
Requirement Condition supporting time
NA
of Job Audit
1.0 Curing Process
With alarm system set per limits (of

I1.3): Continuous recording
Oven control temperature is monitored and recorded Continuous
I1.1 Automatic Yes Conforming - -
continuously by a recording instrument No alarm system : Review and approve Recording by HMI
data every process change and every 2
hours
I1.2 Part temperature shall be sufficiently cool before next Automatic / Manual Manual Each batch Yes Conforming - -
operations (coating, unloading, packing, etc.)
I1.3 Temperature control limits shall be defined to ensure the part Automatic Yes Each process change Continuous Conforming 320 - 355 335
temperature is within the chemical supplier recommendation Recording by HMI
For batch oven / spray processes, prior

Automatic Max. SAT to start of production and every part
I1.4 Temperature (Thermocouple) difference allowed ± Yes change. For automated processes, at Every Lot Conforming - -
5ºC (10ºF) oven start-up, once every 8 hours, and
For batch oven/ continuous processes,

Process time parameters shall be verified against the control prior to start of production and every
I1.5 plan (conveyor / belt, speed set point, batch timer set point, Manual Yes part family change. For automated Every Lot Conforming - -
index time) processes, at oven start-up, once every
8 hours, and every process change
Per oven manufacturer, filter supplier

I1.6 Air filter (if used) change is scheduled Manual NA NA
recommendation
Cure testing is performed per part specification on a At oven start-up, every process or part
I1.7 Manual NA NA
production part, if applicable change and once every 8 hours
I1.8 Coating adhesion test is performed per part specification on a Manual Yes At oven start-up, every process change Every Lot Conforming - -
production part and once every 8 hours
Appearance requirements checks (color, gloss, defects, etc.) At oven start-up, every process change Defects (Every
I1.9 Manual Yes Conforming - -
are performed per part specification and once every 8 hours Lot)
TUS data shall be evaluated to verify the oven is capable of Verification is
I1.10 meeting the minimum curing time and temperature Manual Yes After each TUS being done after Conforming Every Month Every Month
requirements each TTR,

I2.1 Thermocouples shall be checked and replaced per Section P3. 1 and Process Table requirements
Are thermocouples calibrated before first use and within the temperature range in which they will be used ? followed Conforming
Do thermocouples meet the accuracy requirements of the Section P3.1 Tables ? Accuracy requirements to be met Conforming
Is thermocouple usage properly documented as applicable per section P3.1.2 (e.g., date placed in service,
followed Conforming
uses ?)
Are thermocouples replaced in accordance with Tables P3.1.1, P3.1.2 and P3.1.3 ? followed Conforming
Do thermocouples calibration certificates conform with Section P3.1.1.1 ? met Conforming

I2.2 Calibration of instruments shall conform to the requirements defined in Section P3.2 and the Process Tables
Are instruments calibrations performed at the intervals specified in Table P3.2.1 ? Yes, as per calibration plan Conforming
How do you ensure instrument calibrations are up to date ? Yes, as per calibration plan Conforming
Do instruments meet the accuracy requirements specified in Table P3.2.1 as applicable ? Yes Meeting Conforming
Are offset values within the acceptable limits defined in Section P3.2.2 ? Yes Meeting Conforming
Is there a document offset procedure as defined in Section P3.2.2 ? Not applicable -
Does the documented offset procedure indicate who has the authority to approve the use of offsets ? Not applicable -
How is approval of offset documented ? Not applicable -
Do calibration labels conform with the requirements established in Section P3.2.4.1 ? Yes, Meeting Conforming
Do calibration reports conform with the requirements established in Section P3.2.4.2 ? Yes, Meeting Conforming


I2.3 System Accuracy Test (SAT) for all control, monitoring and recording temperature system (instrument, lead wire and the thermocouple (RTD) shall conform to Section P3.3
Are system accuracy tests performed on all oven / dryers control, monitoring and recording temperature followed Conforming
systems ?
Are system accuracy tests performed at the intervals specified in Section P3.3.1 ? followed Conforming
Are system accuracy tests performed after maintenance per Section P3.3.3 ? followed Conforming
How do you ensure the measuring junctions of the test and oven control, monitoring or recording followed Conforming
thermocouple / RTD are within 50 mm (2 inches) of each other as specified in Section P3.3.4.1.2 ?
Do system accuracy tests meet the tolerance requirements specified in Section P3.3.4.1.3 ? followed Conforming
Do system Accuracy Test records conform with the requirements established in Section P3.3.5 ? followed Conforming
I2.4 Temperature Uniformity Surveys (TUS) of all ovens shall conform to Section P3.4
Are temperature uniformity surveys performed annually as specified in Section P3.4.1 ? followed Conforming
Are temperature uniformity surveys performed after oven modification or repair per Section P3.4.1.2 ? followed Conforming
How are oven modifications or repairs documented per section P3.4.1.3 ? followed Conforming
How do you determine whether oven modifications or repairs have altered the temperature uniformity followed Conforming
characteristics of the oven ?
If the oven operating temperature range of the qualified work zone is greater than 170ºC / 305ºF, then were
followed Conforming
the minimum and maximum temperatures tested per P3.4.2 ?
Are readings of all TUS thermocouples and control thermocouples within ± 10ºC (± 20ºF) of the temperature
controller set-point value or other more stringent customer specification, process sheet or technical data followed Conforming
sheet ?
Was the time required to achieve target part temperature within the time limit specified in customer followed Conforming
specification, process sheet or technical data sheet ?

Was the required time at temperature achieved (for continuous / semi-continuous ovens only) ? Yes, continuous oven Conforming
Was the upper temperature tolerance exceeded at any time by any TUS thermocouple or temperature
Not exceed from upper temperature tolerance Conforming
controller thermocouple ?
Was the lower temperature tolerance continually maintained after reaching the beginning of the soak period ? Continually Maintained Conforming
How does the organization internally define suitable time at temperature for determining pass / fail status of
ok Conforming
TUS ?
Does TUS reporting conform with the requirements established in P3.4 ? - -
I2.5 Baskets, belts / conveyors, racks, fixtures and drive mechanisms shall be maintained
How do you inspect for the integrity of the baskets, racks, belts / conveyors and drive mechanism? Check Daily as per Daily Machine check sheet. Conforming
(e.g., wear, perforations, trap points, plugged holes, door gaps, other damage) As per PM check sheet on schedule.
Preventive Maintenance plan available for production machine & Supporting

What is your preventative maintenance program for baskets, racks, belts / conveyors and drive mechanisms ? Equipments. Conforming
What is the maintenance program for mechanical / chemical cleaning of baskets, racks, belts / conveyors and Basket Cleaning is done as per decided frequency. Conforming
drive mechanisms ?
How is each basket or rack uniquely identified for tracking purposes ? All basket are identified with Basket No. Conforming
I2.6 All air filters shall be maintained

What is your preventative maintenance program for air filters ? NA
How do you verify that the replacement filter is appropriate ? NA
I2.7 All process and equipment alarms shall be tested on a quarterly basis at a minimum
What is your preventative maintenance program where alarms are used for temperature, environmental All poka yoke verification is being done on daily basis. Conforming
control, faults, etc. ?.
What are the alarm that are tested and their test frequency ? All poka yoke verification is being done on daily basis. Conforming


I2.8 Process equipment is designed / optimized for "soft handling" of parts
Is chutes lined to prevent part damage ? Lined with Teflon sheet Conforming
What technique(s) are used to minimize drop heights / part damage ? Inclined Teflon sheet is used while collecting the material from the belt to troll Conforming
I2.9 Part transfer equipment is maintained
What is your program to assure cleanliness of belts, conveyors, chutes, vibratory tables, etc. ? Daily 5S activity is being done Conforming
What is your maintenance program for belts, conveyors, chutes, vibratory tables, etc. ? Include in Machine Preventive Maintenance Check sheet Conforming
I2.10 In-process and customer containers are managed and maintained
How do you identify and segregate in-process containers for different processes ? The design of trolley and colour is different Conforming
What is your maintenance program for keeping in-process containers clean and in good condition ? Daily 5S activity is being done Conforming
How to you ensure that the customer containers do not degrade the quality of the coated parts ? Before keeping the finished product in customer container, cleaning of Conforming
(e.g., customer container may arrive damaged, oily, dirty) container is being done
Test equipment shall be verified and calibrated per Process Table K

I3.1
Hand Held Thermometer NA

Lab Oven NA
Travelling Temperature Recorder (e.g., Datapaq or equivalent) Calibration Annually Conforming

Proceed to PT 1

PROCESS TABLE K - Process Control and Testing Equipment Verification and Calibration
All requirements given below are subordinate to applicable customer / OEM specific requirements
The customer may have additional requirements, e.g., inspection testing or greater frequencies. 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. To justify reduced monitoring frequencies, a minimum of 30 consecutive measurements (data points) at stated frequencies
must be documented. If any data points at reduced monitoring frequencies are outside of control limits, then revert back to the frequencies stated under the minimum requirements.
Job Audit Measurements

Condition Condition Actual
Item # Equipment Type Verification Frequency Calibration / Certification Observations /
Nonconforming Nonconforming Measurements
Frequency Comments Range
NA NA supporting time
of job audit
Control chemicals (e.g., Hogeboom Before use - must be checked for Shelf life of chemicals
K1.1 solution, buffers, vibrants, indicators, Daily Conforming shelf life / Expiration date, Conforming mentioned on chemical
surface tension in, viscosity oil) contamination containers
K1.2 Thermocouple Per Section 3 Pyrometry Not Meeting Per Section 3 Pyrometry Conforming Used calibrated
thermocouple
K1.3 Booth Temperature / Humidity Once every 4 hours Every Lot Every 6 months - Conforming Calibration Annually
Controller
K1.4 Circulation / Flow Meter / Pressure At the beginning of production and at Not required Annually Conforming
Gauge every material change
K1.5 Process Air Cleanliness Control Per equipment manufacturer's NA Annually NA

specifications
K1.6 Amp Meter / Volt Meter At the beginning of production and at NA Annually NA
every material change
K1.7 pH Meter Per equipment manufacturer's Daily Annually Conforming Calibration Plan - Yearly
specifications
Once every 4 hours, using a minimum of 2
K1.8 pH Probe buffer solutions near the min and max of Daily Annually Conforming
the chemical control range
K1.9 Conductivity Meter Per equipment manufacturer's NA Annually NA

specifications
K1.10 Conductivity Probe reference solutions near the min and max NA NA NA
of the chemical control range
K1.11 Ion Selective (ISE) Probe reference solutions near the min and max NA NA
of the chemical control range
K1.12 Laboratory Balance Monthly using a minimum of 2 reference Daily Annually Conforming Yearly Calibration Plan
mass standards
K1.13 Atomic Absorption (AA) Before each use NA Annually NA

of job audit
K1.14 Inductively Coupled Plasma (ICP) Before each use NA Annually
K1.15 ION Chromatography (IC) Before each use NA Annually
K1.16 X-ray Fluorescence (XRF) Daily. Thickness and alloy for each Conforming Annually Conforming
combination of coating and substrate
K1.17 Hardness Tester Daily NA Annually
K1.18 Profilometer Daily NA Annually
K1.19 Lab Rectifier NA NA Annually
K1.20 Ultrasonic Cleaner Monthly (e.g., foil test) NA Annually
K1.21 Hand Held Digital Thermometer NA NA Annually
K1.22 Glass Thermometer Visual Inspection before each use Yes Annually Replacement Conforming
K1.23 Pipettees - must be checked for broken Before each use Yes NA
tips
K1.24 Salt Spray Cabinet Daily Yes Annually Conforming Calibration once in a
year.
K1.25 Water Immersion Bath Per Section 3 Pyrometry NA Per Section 3 Pyrometry
K1.26 Freezer Per Section 3 Pyrometry NA Per Section 3 Pyrometry
K1.27 Thickness Tester Every 8 hours NA Annually NA
K1.28 CASS Cabinet Daily NA Annually
Microscope
K1.29 100x fir surface profile Visual Inspection before each use NA NA
500x fir crystal morphology
K1.30 Lab Oven Per Section 3 Pyrometry - Annually Conforming Calibration once in a
year.
K1.31 Muffle Furnace Per Section 3 Pyrometry - Per Section 3 Pyrometry


of job audit
K1.32 Coefficient of Friction / Torque Tension NA NA Annually

Testing (required for fastners)
K1.33 Refractrometer Monthly NA NA
K1.34 Spectrophotometer Monthly NA Annually
K1.35 Color Meter Daily NA Annually
K1.36 Glass Meter Monthly NA Annually
K1.37 Digital Temperature Recorder (e.g., NA NA Annually

DataPaq)
K1.38 Moisture Analyser NA NA Annually
Visual Inspection
K1.39 Filters / Sieves - blast media NA NA
Lab - before each use
distribution, impurity removal
Production - each time media is added
K1.40 Linguard® 101 Meter Visual Inspection NA Every 3 months
K1.41 ORP Meter (in process) When difference is greater than 30 mv NA Annually
when compared to lab meter
K1.42 ORP Meter (Laboratory NA NA Every 30 days
K1.43 Line viscosity cup or equivalent Every 14 days NA NA
K1.44 Master viscosity cup or equivalent Every 30 days NA Annually Conforming Once in a year
K1.45 Weight per Gallon Cup / Hydrometer Before each us NA NA
K1.46 Tape (adhesion testing / dust residue Before each us NA NA

check)
K1.47 Scribe Tool Before each us NA NA
K1.48 Blacklight for UV tracer identification Before each us NA NA
K1.49 Timer / Stopwatch Before each us NA Replace Annually Conforming

Cqi - 12 - Audit Report of Aum Dacro 24.06.2023

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Cqi - 12 - Audit Report of Aum Dacro 24.06.2023

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Special Process: Coating System Assessment Version 3 Issued 07/2020

Special Process: Coating System Assessment Cover Sheet

Facility Name: Aum Dacro Coatings

Number of Nonconforming Findings from Section 1 and Section 2: 0

© 2020 AIAG (Automotive Industry Action Group)

Number of Nonconforming Findings in the Process Table(s): 0

© 2020 AIAG (Automotive Industry Action Group)

CSA SECTION 1 - Management Responsibility and Quality Planning

Management Responsibility and Quality Planning

B.Tech Mech with 10 years experience in Geomet

Section 1 - Management Responsibility and Quality Planning

Yes, procedure for APQP QAD-D-09 is available and

Section 1 - Management Responsibility and Quality Planning

Production - Abhay Singh

© 2020 AIAG (Automotive Industry Action Group)

Yes, F06 (QAD-P-09) Common PFMEA was evident,

FMEA F06 (QAD-P-09) verify for special

Yes, F06 (QAD-P-09) FMEA was revised for double

© 2020 AIAG (Automotive Industry Action Group)

Section 1 - Management Responsibility and Quality Planning

Yes, Common Control plan, F01(QAD-P-09) Rev.15,

Production - Abhay Singh

Section 1 - Management Responsibility and Quality Planning

Yes, Customer standard and specification are

Customers are providing the standards &

© 2020 AIAG (Automotive Industry Action Group)

New standard & specification are being received by

Section 1 - Management Responsibility and Quality Planning

Section 1 - Management Responsibility and Quality Planning

Change is happened in process or machines. All are

Analysis and corrective action and effectiveness

Section 1 - Management Responsibility and Quality Planning

Section 1 - Management Responsibility and Quality Planning

Records are retained as defined. Minimum 3 years -

© 2020 AIAG (Automotive Industry Action Group)

Section 1 - Management Responsibility and Quality Planning

Section 1 - Management Responsibility and Quality Planning

This is the first internal self assessment done on

© 2020 AIAG (Automotive Industry Action Group)

Section 1 - Management Responsibility and Quality Planning

Through rework material tracking card in pink

Section 1 - Management Responsibility and Quality Planning

Yes procedure available

Replying to Cosmo India - Black Spot in hole area

Section 1 - Management Responsibility and Quality Planning

Section 1 - Management Responsibility and Quality Planning

© 2020 AIAG (Automotive Industry Action Group)

Control of Non-conforming products procedure

© 2020 AIAG (Automotive Industry Action Group)

Section 1 - Management Responsibility and Quality Planning

Work instruction available for process startup.

Section 1 - Management Responsibility and Quality Planning

• The organization shall provide employee training for all operations.

Section 1 - Management Responsibility and Quality Planning

Section 1 - Management Responsibility and Quality Planning

Verify B/D maint slip, B/D was happened on

© 2020 AIAG (Automotive Industry Action Group)

Section 1 - Management Responsibility and Quality Planning

© 2020 AIAG (Automotive Industry Action Group)

CSA SECTION 2 : Floor and Material Handling Responsibility

Incoming Material register F02(QAD-P-01)

Section 2 - Floor and Material Handling Responsibility

Section 2 - Floor and Material Handling Responsibility