cal-23 Special Process: Molding System Assessment 1st Edition » Insight » Expertise » Results The Catalyst for Peak Performance | AIAGAIAG gatas Special Process: Molding System Assessment “The Catlyt for Pook Perforce” ‘Version 1, Issued 03/2014 ABOUT AIAG Purpose Statement Founded in 1982, AIAG is a globally recognized organization where OEMs and suppliers unite to address and resolve issues affecting the worldwide automotive supply chain. AIAG's goals are to reduce cost and complexity through collaboration; improve product quaity, health, safety and the environment; and optimize speed to market throughout the supply chain. AIAG Organization AIAG is made up of a board of directors, an executive director, executives on loan from member companies, associate directors, a fulltime staff, and volunteers serving on project teams. Directors, department managers, and program managers plan, direct and coordinate the association's activities under the direction of the executive director. AIAG Projects Volunteer committees focus on business processes or supporting technologies and methodologies. They conduct research and develop, publish, and provide training on standards, conventions, standard business practices, white papers, and guidelines in the areas of automatic identification, CADICAM, EDlielectronic commerce, continuous quality improvement, heaith focus, materials and project, management, occupational health & safety, returnable containers and packaging systems, transportation/customs and truck & heavy equipment. “AIAG PUBLICATIONS {An AIAG publication reflects @ consensus of those substantaly concemed wit is scope and provisions. An ‘AIAG publication i intended as a guido (o ald tho manufacturer, the consumer and the general public. The ‘existence of an AIAG publication does notin any respect preclude anyone from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the pubiction. (CAUTIONARY NOTICE AIAG publications are subjct fo periods reviw and usors are cautioned (o obain the latest edons. MAINTENANCE PROCEDURE Recognizing that this AIAG publication may not cover all crcumstances, AIAG has established a maintonance procedure. Please referto the Manianance Request For a the back of his document to submit a request. Published by: ‘Automotive Industry Action Group 126200 Lahser Road, Suite 200 ‘Southfield, Michigan 48033 Phone: (248) 358-3570 » Fax: (248) 358-3253 APPROVAL STATUS The AIAG Qualty Steering Commitee and designated stakeholders approved his document for publication in March 2044 AIAG COPYRIGHT AND TRADEMARK NOTICE: The contents of al published materials ar copyrighted by the Automotive Industy Action Group unloss otherwise indicated. Copyrights net claimed as fo any part of an original work proparod by a U.S. o state govornmant ofcer or amployeo as part of te ‘person's offeial duties. Al ights are preserved by AIAG, nd content may not be altered or disseminated, published, or Vansfered ln pat of such content. The information isnot o be sold in part or whole fo anyone within your organization orto another company. Copyright intingoment isa violation of foderal aw subject to criminal and civil penalies. AIAG and the Automotive Industy Action (Group are registered service marke ofthe Automotive dusty Action Group, © 2014 Automotive Industry Action Group Sane: 978 1-60584 209 7cal-23 Soest oct deg Syston Assesaman AIAG» Version 1 Issued 03/2014 “The Catalyst for Peak Perfoeranca™ FOREWORD Automotive Industry Action Group (AIAG) committees are made up of volunteers from member companies in the automotive industry, This edition is a compilation of best practices developed collaboratively by industry experts from OEMs, Tier | suppliers, and molding suppliers and represents an ideal practice. In the Molding System Assessment, the words “shall”, “requirement”, and “should” indicate a requirement or recommendation for purposes of this self-assessment only. ‘The main task of technical committees is to prepare Automotive Standards and System Requirements. Draft documents adopted by the technical committees are circulated to the Steering Committee and industry experts for review and consensus approval. Publication of the documents requires approval by the Quality Steering Committee.AIAG caves ‘Special Process: Molding System Assessment “Tho Catalyst for PoskPortorrares™ Version 1, Isued 03/2014 ACKNOWLEDGEMENTS ‘The Quality Steering Committee would like to acknowledge and thank the following individuals and their companies who have contributed time and effort to the development of this document. Ken Campbell Ventra Plastics Kevin Keller Robert Bosch LLC Vimi Khanna Chrysler Group LLC Ed Luibrand Chrysler Group LLC Donita Morgan Toyota Motor Engineering, NA David Post Delphi Corporation Carey Price ARE. Accessories LLC Daniel Simoes Ford Motor Company Brazil David Toutant Robert Bosch LLC Daniel Williams General Motors Company Larry Xu Ford Motor Company Ashley Claus AIAG Karen Whitmore AIAGVersion 1, sued 0972014 Tho Cotaat or Peak ortormana TABLE OF CONTENTS ‘ABOUT AIAG FOREWORD ‘TABLE OF CONTENTS. INTRODUCTION .. Genera, PROCESS APPROACH ‘MOLDING SvsTEM ASSESSMENT GOALS ASSESSMENT PROCESS... ASSESSOR QUALIFICATIONS. (OTHER Requitemenrs. 1 SCOPE L.A GENERAL ssn 1.2 APPLICATION... 2 THE MOLDING SYSTEM ASSESSMENT PROCEDURE .. 3 SPECIAL PROCESS: MOLDING ASSESSMENT. [APPENDIX A ~ PROCESS TABLES. Process Table A: Injection MOlBINg senses vo rene 34 Process Table B: Blow Molding 39 Process Table C: Vacuum Forming 44 Process Table D: Compression Molding 47 Process Table E: Transfer Molding Thermoset Matera)... 50 Process Table F Extrusion. zi Process Table G: EQUIPMENT Process Table H: Part Inspection and Testing, GLOSSARY...AIAG gauzs ee ‘The Catlyet fx Peak Parfoareca™ Version 1, Issued 03/2014 INTRODUCTION General ‘The work of preparing CQI-23: Special Process: Molding System Assessment was carried out through the AIAG Molding Work Group. These molding requirements are complementary to customer and product standards. ‘The Molding System Assessment can be used to assess an organization’s ability to meet the requirements in this assessment, as well as customer, regulatory, and the organization’s own requirements. The Molding System Assessment can also be used between an organization and its suppliers. In the Molding System Assessment, the word “shall” indicates a requirement for purposes of this self assessment. Failure to meet the requirements results in an assessment that is either “Not Satisfactory” of “Needs Immediate Action”. The word “should” indicates a recommendation. Where the term “such as is used, any suggestions given are for guidance only. Process Approach ‘The Molding System Assessment supports the automotive process approach as described in ISO/TS 16949, Molding System Assessment Goals The goal of the Molding System Assessment is the development of a molding management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain. ‘The Molding System Assessment, coupled with an internationally recognized quality management system and applicable customer-specific requirements, defines the fundamental requirements for molding ‘management systems. ‘The Molding System Assessment is intended to provide a common approach to a molding management system for automotive production and service part organizations, Assessment Process Ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to reexamine the continuing compliance with the Molding System Assessment. Each assessment shall include a review of the organization's systems using the Molding System Assessment. Successive Job Audits (Section 3.0 of this document) shall sample parts from different automotive component ‘manufacturers that require compliance to the Molding System Assessment document. ‘The assessment shall use the process approach to auditing/assessing as identified by the requirements of ISO/TS 16949,cal-23 Seat rete mens ho ars AIAG & Version 1, Issued 03/2014 Tha Catalyet or Peak Perfomance” Assessor Qualifications ‘Assessor(8) shall have the following specific experience to conduct the Molding System Assessment: 1, Bean experienced quality management system (QMS) internal auditor (for example, ISO/TS 16949, ISO 9001) 2. Assessor shall possess molding process knowledge. Evidence shall include a minimum. ‘of 5 years’ experience in molding processes or a combination of formal engineering, ‘education and molding experience totaling a minimum of 5 years. 3. Assessor shall possess knowledge of and be familiar with the application of automotive quality core tools including statistical process control, measurement systems analysis, part approval, failure mode and effects analysis, and advanced quality planning. Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in #1. Other Requirements ‘The organization shall keep records as evidence of compliance to the requirements identified in the Molding System Assessment, as well as all appropriate action plans to address any unsatisfactory ratings. ‘These records shall be readily available for review by any customer requiring compliance to the requirements within this document.AIAG.» gaze “The Catatst fr Pok Portrmance” Version 1, lsved 09/2014 1 SCOPE 1.1 General ‘This document specifies process requirements for an organization or its suppliers performing applicable molding, who need to: ‘+ demonstrate ability to consistently provide product that meets customer and applicable regulatory requirements, and ‘* enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system. The Molding System Assessment is applicable to sites where customer-specified parts for production and/or service are processed throughout the automotive supply chain. 1.2 Application Alll requirements of the Molding System Assessment are generic and are intended to be applicable to all organizations performing the molding operations addressed in this document, regardless of type, size, and product. Eight process tables have been developed and the appropriate table(s) is to be referenced during the assessment. The process tables are specific to molding processes as noted below: Process Table A — Injecting Molding ‘Receiving Inspection ‘© Storage and Handling © Material Drying * Recycle/Regrind Material * Color Management ‘+ Molding Process © Quality Control Process Table B ~ Blow Molding © Re ving Inspection © Storage and Handling © Material Drying + Recycle/Regrind Material * Color Management * Molding Process + Fluorine/Sulfination Treatment * Quality Controlcal-23 Sree ces: lng System Asean AIAG Version 1, Issued 0372014 Process Table C— Vacuum Forming Receiving Inspection Storage and Handling Forming Process Quality Control Process Table D ~ Compression Molding © Receiving Inspection © Compounding * Storage and Handling © Molding Process © Quality Control Process Table E - Transfer Molding (Thermoset Materials) © Receiving Inspection * Compounding and Preforming * Storage and Handling * Color Management * Molding Process © Quality Control Process Table F — Extrusion Receiving Inspection Storage and Handling Material Drying Recycle/Regrind Material Color Management Extrusion Process Quality Control Process Table G — Equipment— Process Control and Testing Equipment ‘© Process Equipment ‘© Secondary Equipment ‘+ Minimum Required Testing Capability PROCESS TABLE H - Part Inspection and TestingAIAG ‘The Cattyt for Pook Portrmarce cal-23 ‘Special Process: Molding System Assessment Version 4, Issued 03/2014 ‘These Process Tables (A through H) contain requirements for: 1 2, 3, 4, Process and Test Equipment Process Monitor Frequencies In-Process/Final Test Frequencies ‘Test Frequencies The Process Tables specify the tolerances of process parameters and the frequencies for checking process control parameters and parts.eai28 AIAG Specie Process: Molaing System Assessment a Version 1, sued 09/2014 The Catalyst for Peak Pororanes™ 2 THE MOLDING SYSTEM ASSESSMENT PROCEDURE 1. Obtain current copy of CQI-23 Special Process: Molding System Assessment from AIAG. 2. Identify all molding processes to which CQI-23 Special Process: Molding System Assessment applies (see CQI-23, 1.2). Record these processes on the Molding System Assessment cover sheet. 3. Complete the Molding System Assessment, including sections 1, 2 and all applicable process tables to determine the level of compliance. A minimum of one job audit (Section 3) shall be performed during each assessment, 4, Address each “Not Satisfactory” item and determine corrective action, including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. 5. “Needs Immediate Action” requires immediate containment of suspect product. Address each “Needs Immediate Action” item and determine corrective action(s), including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained, 6. “Number of Process Table items identified as failed in Comments/Observation column” to be reported. 7, Assessments shall be conducted annually.AIAG 2 gona ‘Special Process: Molding System Assessment Version 1, Issued 03/2014 “The Gatlyet fr Penk Pater 3 SPECIAL PROCESS: MOLDING ASSESSMENT INSTRUCTIONS FOR COMPLETING THE COVER SHEET Coven Suter... INSTRUCTIONS FOR COMPLETING SECTIONS 1 ~2.. [MOLDING SYSTEMS ASSESSMENT... INSTRUCTIONS FOR COMPLETING THE JOB AUDIT.. 408 Auorr. smennnsnenennen dT ole“1d cal-23 Spas rots: Mong Sytum Assesment AIAG» Version 1, sued 03/2014 The Catalyst for Pook Fr INSTRUCTIONS FOR COMPLETING THE COVER SHEET 10, uM. Facility Name: Name of the facility being assessed. ty. The facility may have several buildings or physical the same general area, If there isa separate management team (Quality Manager and ) or different management system, then these locations shall be considered as separate facilities. Address: The street address of the facil additional information. ty being assessed; P.O. Box numbers may be given as Phone Number: The phone number ofthe facility. Ifthere is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used. Fax Number: The fax number of the facility. Number of Molding Employees at this Facility: The number of employees, salaried and hourly, associated with the molding operation at this facility. Captive Molder (Y/N): Enter “Y” ifthis facility molds components for their own company. Enter “N” if the company does not mold any components for their own company. ‘Commercial Molder (¥/N): Enter “Y” if this facility molds components for companies other ‘than their own company. Enter “N” if this facility does not mold any components for other companies. Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be used to avoid confusion with different numeric formats. Example: May 3 ~ 4, 2016, Date of Previous Assessment: List the date of the previous Special Process: Molding System Assessment of this facility, Type(s) of Molding at this Facility: Place a checkmark to designate all molding process(es) performed at this facility. This information determines the appropriate Process Table that shall be used during the assessment. Processes not listed on the cover sheet are not part of the Molding System Assessment, Current Quality Certification(s): The molder shall list their current quality certifications, e.g., ISO/TS 16949, ISO 9001. Certifications may be from 3rd party sources or customer quality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given, Date of Re-assessment (if necessary): If “Not Satisfactory” findings were observed from the original assessment, then the molder shall address each item and determine correct action, including root cause analysis and implementation of the corresponding corrective action(s). The date of the re-assessment shall be given here, and the appropriate Question(s) from Sections 1 — 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the “Number of Not Satisfactory Findings” shall be modified as appropriate. Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available, of the principal participants from the molder’s organization. Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), if available, of the auditor(s)AIAG os Special Process: Molding System Assessment ‘The Catalyst foc Pek Performs Version 1, lsued 0372014 15, 16. 17. Number of “Not Satisfactory” Findings: Enter the number of “Not Satisfactory” findings observed during the assessment, Number of “Needs Immediate Action” Findings: Enter the number of “Needs Immediate Action” findings observed during the assessment. Number of “Fail” Findings in the Job Audit(s): Enter the number of “Fail” findings observed from the job audit. Number of Process Table items identified as failed in Comments/Observation column: Enter the number of failed findings observed in the completed process tables. -13-CQI-23 Special Process: Molding System Assessment Version 1, Issued 03/2014 AIAG.» “The Catalyst ior Pook Purtorrance” Cover Sheet [Special Process: Molding System Assessment Foamy ae erat [Piss Roe frarrameer aa] of Wang Prosaanas a Precise Table (Rober of aang ERIS wa Fae fneeton lang [Comrise [Prsenan ToBI Procsae Tapa ea [roceee Tabs aT [carer Guany Careatoner a Re RSA TOS [Personnel Cora [ite era SE Fa [Rambo sacs nests Rao FaasAIAG 2a ganz “The Catv fr Penk Porlorsnco” ‘Version 1 Issued 03/2014 INSTRUCTIONS FOR COMPLETING SECTIONS 1-2 Sections 1 -2 contain questions and the requirements and guidance for each question. The Sections are: Section 1: Management Responsibility & Quality Planning Section 2: Floor and Material Handling Responsibility ‘The assessor shall assess the molder’s compliance to Sections 1 — 2 by comparing the evidence presented by the molder to the requirements listed in the “Requirements and Guidance” column, NOTE I In the “Requirements and Guidance” column, the word “shall” indicates requirement and the term “such as” indicates that any suggestions given are for guidance only. NOTE2: The “Requirements and Guidance” column will indicate to the assessor when the Process Tables are pertinent to the Questions. When the Process Tables are pertinent to the Question, the assessor shall assess the ‘molder’s compliance to the specified section(s) in the Process Tables. NOTE3: _ If the question is not applicable to the molder, then the assessor shall place a checkmark in the “N/A” Assessment cohumn. If the observed evidence is in compliance to the question, the assessor shall note the evidence in the “Objective Evidence” column and place a check mark in the “Satisfactory” column. 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Nocorformng hd area shat be ear, [senate to manta sogrogaton of uch maton, Juowssessy warshs Buypjoyy :sse2044 Je/20ds €2-109 ‘rozieo pense | vOReA,te ‘Special Process: Molding System Assessment (General Facility Overview) x} Nomber ‘vestion crea ayo ority neice or improper rite pas)? Requirements Ireppartsinieentze |e molder snl have decanted procedures 0 procees io educo risk of | denty and mentor wap pts for esch ‘rie prs (raperoprate, |pocemeqapmert Monorng of penal ap pant sna cei for every par changeover, nual Sattactory [rot satista Needs immediate ro containers Heo ot appropri mate? [consinersnasing customer product hat be fre of nsereprate matenal. Ate emptying and before r- lang containers, contains shall be spect 0 Jena rat pare and inappropriate mater have lsenseroned Te eure of nappoorate ate sha be lenited and adsense Peto ansure notre rencorerming molded pats or appropte lare operators rained n rte naning, continent [aston ana product seregaion nto vert ofan lequpnen' emergency noun power fae? Untamed or emergency downtime great razas the st improper pressing. Operator al be ined nett handing, conten acten, and rout searegacon he ever cf an equpent emergency Wer isuczonsspecitcalyaacrsar ports yee ct equipment emerges and flues shal be laccessbe to ana unaerion by equipment operators. plone rested al elements fhe process Evioeno® snalenstsnowing poston and raceabiy of teres pect ste handig, storage and [pckaging eat > [recave prague quai? lhe nce in srocees handing and hgping soos shal be eeesse for kof per arg or her uaty cones, Lwoien, juoussessy woysks Buypjoyy ‘ss000x4 [2/00ds £2109 ‘rLozieo pense _SuRaEpRI a CHAI ULst Special Process: Molding System Assessment (General Facil Overview) ‘ueston a ‘ueston equrments snd Guance objective Ensenca Irae eanines hvseecingendcnnent a bye or claniness fring enonan na ta cnauone ocmsing aio Roamer econ [etter aoa The me wx ewe [scons ante tact on sty. A uote ea ant ay fevnsreepg sty sas bese tne nd fered ey Irces conte parrntars al mone er Weepocescontl roan spechesin roams Tauee Comper 2a fernsteerontoed pe entry equprent wih os sd rm ngs Feces spntecin [Tey tert aire. A score Tet frson sat very pecs arate Ivano [rere rose aston paren bom ox ot aie Aietefomtlencteton Dende coouns poses pos Prrametr Finer cosmertd evans ut enon parse fotowed |rest Frequencies natn pedomed a spec in oo Semen : Sechen uence eset orcas sca tamer, Se ores ee aw legmicimceminen a cin at hans Iie reviewed, proved ana documented. [Reterto Process Tales for roquency of checks 206 Losing otiapecsn ee leaning nme inezacton ara chal be sunt to ftw evauson of apart sacs, Theta fat ue atanges wo rectde spot ging, glare freien So nenng aria Juauissessy wia}s/s Buypjow :sseo0g jeoeds €2-109 ‘i020 panes] "| UOISIOA 5-26- cae AIAG Special Process: Molding Systm Assessment a Version 1, Issued 00/2014 The Catalyst fr Pook Poforre INSTRUCTIONS FOR COMPLETING THE JOB AUDIT ‘The organization is to complete a minimum of one molding part job audit during each assessment. This should be done preferably on a part identified for one of the customers requiring compliance to this document, More part job audits may be done if time permits. Preferably, safety or critical parts should be audited. This may not be easily determined with fasteners, especially ifthe fastener manufacturer does not identify the end customer (auto manufacturer, tier one, etc.) It is recommended that the job audit be performed at the end of the molding system assessment. ‘The job audit is not the only or main focus of the Molding System Assessment. The other two sections on ‘Management Responsibility and Quality Planning, and Floor and Material Handling Responsibility are equally if not even more important, The job audit of one part, one molding process, is not sufficient to use as a basis to complete the other sections of the complete Molding System Assessment. ‘The job audit is a compliance type audit/review of a specific part and its related paperwork and processing, including molding equipment and processing records for that job from the beginning receipt ofa part through processing in the molding operation and inspection to packaging. Parts shall be taken from the shipping area at the dock or the end of the molding operation. If an automotive manufacturer's partis not available or identifiable, then parts from other customers requiring compliance with this document shall be used for the assessment. The specific molding processing parameters (applies to 3.6 in the Job Audit) that are required in the job audit shall be added to the job audit form. This can be done by reviewing the customer specification(s), ‘the Control Plan, the FMEA, and the floor work/job order. Each processing step shall be reviewed for proper production records/compliance/inspection, ‘These steps can be compared to those in the Mol System Assessment for the actual job/molding process being reviewed for compliance,“ae Section 3 - Job Audit - Finished Product Review ob enti Customer Shop Order Number: artNumber Part Descrinton Molding Requirements: Rai eb (Sop) Ores or Molding Sytem | Customer ot tera eto | AetalConction | Pass aa dye fezoeeren Requremest Reference Dosumerinton | recive Eisen) | Fa NA Question # ea | contract review end sdvanced quay a a1___Panning, FMEA: Conta Plans tn i wn Pace an prormed by qaled 13 feat? 14 ‘es the molar have the proper 32 customer specifications for the part? * Na Is tere cocurented evidence of 33 |Receiving Inspection? = satel entation (par raibor. Fl] > 4 [rimbers, convact number, ee) eal frais reughout te mola 23 process? she proper procedure or process 18 spoctaton teed? Retro Process 13 35 [Tables for spect parame. List 21 parameters that were void mus aut | 2:91 [nthe spaces proved blow 28 pny gor aamUnPAL ed jueuissassy weysg Bulpjoy :sse201g Je;9edS £2109 F10RIe0 panes] 1 IRIOn, 9Job de customer: Shop Order Numba ar Numb Part Description Molding Requirements Tai {ob Shop) Ore or r Sa Noisng Sysem | Cutter orinemal cb isrep)Orserer | penn Conaion | Pass esac as ssomert Rexurement Reerence Doaimentaton | (opetie Ewdence) | Fal NA Question # ae reco Proce 75 ___[Eechpar ay bave ne or nore ruremeria detained by he molng speeaton a0 [et ene poet napecton 2% |paramustmeetoahequremer Usteach requaent bow rd vate. a 214 (Listed below are some examples) 961 [Reauroment wt Feanenos Test requeny or aunty seeton ot artes seceteaen ‘FHORIB0 panes | WOO juowssessy weyshg Buipjopy :sS920/¢ [2/20ds oy He £2109 5‘Section 3 - Job Audit - Finished Product Review Job Identity: Customer: ‘Shop Order Number: Part Number: Part Description: Molding Requirements: Question #| Job Aueit Question Rated Molging System ‘Assessment ‘Question # Customer o internal Requirement Job (Shop) Order oF Reference Documentation Requirement ‘Actual Contion (Objective Evidence) Pass! Fail WA\ 362 Requirement: Color [Test Methoats) [Test frequency or quanti [Selecion of samples: [Specifeaton: 363 Requirement: Gloss [Test Method: [Test requency or quanti [Selection of samples: Specttcation 3a Requirement. Fash [Test Methods: [Test frequency or uantiy [Selecion of samples [Specifcaton: 9 79840) SAEED OL Juowssossy wayshs Bulpjow :ssao01g jeoeds £2109 "T0RIeD pense} woRIep“oe ‘Section 3 - Job Audit - Finished Product Review 1b Customer: ‘Shop Order Number: Molding Requirements: Qveston | Job Audit Question Rarated Molcing System ‘Assessment ‘Question # Customer or Itornal Requirement Job (Shop) Ordor or Reference Documentation Requirement ‘Actsal Condition (Objective Evidence) Pace / Fal NA) 385 [Requirement Dimension [Test tethod [rest requency or quanti [Selection of samples: [Speciication 386 [Requirement Appearance [Test Method: [rest requency or quantty [Selection of sampes: Specification 367 [Requirement Customer Speco [reat motnoat [rest requency or quanti election of samples ieaton £2109 10zie0 Panes | woRen juowssessy wesshs Bulpjow ‘sse0014 [erDeds rey ehie9 OL 9ae Section 3 - Job Audit - Finished Product Review Job Identity: customer: ‘Shop Order Number: Part Number: Part Description: ‘Molding Requireme Job Audit Question Molcing System “assessment Question 14 18 ‘Customer oF Intomal Requirement 40b (Shop) Order or Pass Fail/WA| {ney authorized? ‘a7 [Were eporopriste process steps signed % jor? 23 2n1 ‘ae |Werealtinspecton steps, as documented] 12 ln the Conte Plan performed? 4 12 9 [ete stepsloperatons performed that a |were not secumented in the ContolPian?| 1 72 14 310 _|!faddtions! stops were performed, were a an loves the governing specification alow Ieprocessing or rework? ean YER FAMED OA Juouissessy wasdg Bulpjow :sse20ud jeloeds 02ie0 PERSE | WOON, £2109“te Section 3 - Job Audit - Finished Product Review deb identi: customer: hop Order Number, Part Namba: art Description: Molsing Regimes: rail {oo ap Oreo wading Sytem | Care or al cu condien | pass? Javetions] dob Aust veston ed etrene ecmenaten | Rell ondon | ras) | Sossn Regurenent | (Oneshe were) Te edorwan can he a a2 [fenteatn sonra etctnepocess| 21% Serre ara [stp cariticaon sped yan ve td al ca [te pr and contr reo 7 Inpeepsat nj oct? 28 218 |wepactagng ronments tontecr | 29 ae [repo pacapete nine nied | 28 210 fponsoraimaged tor romp, wor tow! 27 Erver pect cts 2 2:17 nr te prs roy ea 33 218 [wereneconaines ropetyabent | 33 ‘yiozrbo panes) uorsion Jusuissessy wosshs Buypjow :ss020/4 [ej00dg ana a eA BUD £2109 5AIAG galas eee Version 1, lssued 09/2014 “Te Catalyst for Pook Perforce” APPENDIX A- PROCESS TABLES PROCESS TABLE A: INJECTION MOLDING... PROCESS TABLE 8: BLOW MOLDING PROCESS TABLE C: VACUUM FORMING .. PROCESS TABLE D: COMPRESSION MOLDING PROCESS TABLE E: TRANSFER MOLDING (THERMOSET MATERIALS). PROCESS TABLE F: EXTRUSION. PROCESS TABLE G: EQUIPMENT PROCESS TABLE H: PART INSPECTION AND TESTING 33“re saya pang can epee) x fe [vet se m2 lnwonne none oie ler ornonat (rises Sa yoo Inge ponatartanas ea noarerten enon [emara con enramen| [esomens we fone nares leeconaar ‘rozeo pense) | uma €z-109 jUoUISsessy wersks Bupjoyy :889201¢ |e;eds Bujpjoy uopoefuy :y 21921 Sse901g Pog 8G OAD“se PROCESS TABLE A - Injection Molding [rmauirment gen ow ae sorte fo cestmer spec egorenents |rnecatomer may hae dona equrenen, eg, apacton tring, renter aque, tz When pefrming eo auth sors very mer conforming custome eaten. |rmnonum requremers re not met prose supporting recor uty ata conden. wossion rome | Syme cmaeeProcee Steps ‘ype tone Mentor Freueney |eeqen ao ore econ stant ornate 211 pans Veta ty ed prea woo are ma | it [oumengnsnanenscuvepemnnnen beet hewneee as | ER ene ere he cro mt | femme eons fem hat nsetne 2a ‘woe, juauissessy wo}s/s Buypjow :sse201g 12/9eds ‘7r0zte0 pons-9e- PROCESS TABLE A- Injection Molding ceqdrments ln nose abort octamer pec rogue [rhe coamer my hav atone ©, spcion tng pet Pequncie, te, When pertmin ecb st te sudo shal vert oder is onoingt uomer equa. [tetnan eqdremets rot nt previ spporngctd ony el ono, sa | 2h fromm [emma yar | 138 [eset tea satin sty petacthetet lew nd mae tring fresno assray [etaree yea fren rain ma ei rs) fost EEeenndrtantoe yo Jearcciec erty prcesssetngepintsenpsteet Mont _eoe im loaner. secre Easonenegim enty | tig. ttre Sees) coco rr mes jens npr fama oe os Tong ra renter eae Foal wate poe £2109 ‘yL0zib0 panes 'y voIsen, juauIssessy we}shg Bulplowy :$6820/¢ jej2eds. REP EON OL“le Saunas ¥e0g Oy AMEED OL Pernt corso Coe ona ne Juswissessy wo}s/s Buypjow :sse001q Je/90ds 710er60 Pens "| UOIIEA €2-109-8e- PROCESS TABLE A- Injection Molding [tretone her baw suborder te ene [citer my hv a emer. pce, rat ncn Wh pon jc eh mtr cooing eee [minim eran ae not et roe sparing cot oft ail ono, roe —| re a st Fey mera — amor Ragoremert | AcrniConaon | weninam Reatrnent | Acttooaton | Pas /Fal! was. & [pwn toetatio) jot force erasure vase | 2 ftpetenoe puns patron ale een ncemerere La a ara 211 |Oometons: |Maruat [eayensen See ie a | some bertereeneo rae fest £2109 ‘PHOZIED Pane | WORE juewissessy we}shs Buyplowy :sseo01g [e22d5 “ORO yong AEN eH S0VIV“68 PROCESS TABLE 8 - Blow Molding [regan gen bw resort ctr eece gure |e car mye nna quay, hap ting, trun, When ping ho au dtr sa ety ler ican 2 cetoereguena [tm mpm ae tnt ow peti cn jut ae oor roncionsennt neeten cneocat rere fee tons | Spo coman Pree Spe “ye etconet Hortonmg teqency Wninam Rogirment | Acta Conaton | uinam agurement | Aca Conation | Ple/ Fal! i os | Egmeowmereecnnaioe fae = w | 2 Eeeeemcmnarase = ————— es beiges «| 3b re " Sarre a | dh penne oe a B Easy wr | fesemeeeem neem wt | fsinceom Lanes bv or | th re ig einen Pree nr metre ssn rt i [er mono Bulpjow Mojg :g 8/921 SS2204q SRE FAMED €2-109 juewissassy we}shs Bulpjow :Sse20/g Je}2edS 0zie0 Pane} Woon,sisee — ene | Soe onagorroces Ss pe ot conwot Honoring rue, orca Mismum Requroment | Achat Conaton | Mnmuregurwment | ActaConiten | (255/F3| ro Se eee oe orl cune Ce ee ee fxn: en ea ws Winters snr are Romain [ao focrerztinemente epee oe ein (corr ncon sez | 21 ipemteniometanseadercenn pecan) — fit fn ge 013 | EE fememvmynnnaeortpatcnseemtamtaten fn! later cee | lpseamnasern cet fatnetcnet Ie roe 1 omarion tintin ten aeprig tng apts 2h festa ws |anstcut [satupant cone ‘102/60 pense“ UOISOA €Z-109 duewssessy worsks Buipjoy :sse201q jejoedg soumnopag og =] HARD OL <= OVIVIr oot [2h parent sey Janssens i cione cor | 1 [rmetatoes sonata se romaine tt tment 2 motemversare weet oa | EE fount nan emetic) oeeremearee we was JF |eioerene trnpeatte fr =” at en | moral verscaso: daly 14 et aatngeatie meng aa arene | is SRE on mat a ik Rairareara eevee [emeterece Ea _[naedaagodadconermee eee carer we fing tran ere [Sse ard ay Soma yeaa 5) NED AL sse00id je}00ds Jueuissessy wiajshs BuIpiow : *7102/60 Panes} wOISIOA £2109“42 Cal-23 Special Process: Molding System Assessment Version 1, Issued 032014 AIAG» “The Catalyst fr Peak Forforance™ I I | = Eo | i | i | i | | = Lo caeniroces Spe ij be 1 rains never oe “inn nents otk pre springer ystems, PROCESS TABLE 8 - Blow Molding [erent hen wae nora comer pete equa [ne cure sy hae tonal urumen tet tig reheat. Man paring to ae rsa ey ee caning ator gure“r i i é = |star-up and once every hour Hh ecmmenn fe face z = | bee - =n : =| a jo fom lexooaemons : = | een low lento : . Sssoramear a | Bi [tamer aces aoe 3 & Ewer ; v —— ag a| 2 be lserasetet | a3 Fo a) fg a8[n= cents men re meng ro [sceneries worn wn mre font ne ed eee fret 22 | 2h featommetcrtaninten nt xa a imate omer i eat crete tea) on a yore lewicmar nest on nape sed sth ‘etn ‘loz pores | waRIeA £2-109 quewssessy Wejshs Buipoy :sSe204q /2/99dS Bujurioy winnoen 29 01ge1 8802014 as PAG AID OL S0VIV“sb PROCESS TABLE C - Vacuum Forming ‘noses pen ow a sorte citonnr sce erent inte may a ein! agrees 9, npn eo, grater agent, When pun eo aur sal ey oer ofoming cst eqns ontorng Feguosy — ‘Minium Requirement | Actual Condition | Minimum Requirement | Actual Condition Pome |e pean fo bssesctemre 22 | HE ferenserennemeenrnen fer sem we | iE momen = -— z t af 2 eee Io an | ES enpeee-omerteimecte amy fon lees som cr | 2 [nwttmmeueemnsertsscrtratime fem lege co | 1 enema nrtnne sine Los Lg nemwn -)2———— Lon Lemon ow is |ickd cove speed pustomstc. [asin na te cant is JPtug temperate, start time and speed (W appfcable) Jarome JAtetxtwp. snd ster ong, SS Juawissessy wiajshs Buypjow :sseood rejoeds "FiO2IE0 PORES] LBA e210.or PROCESS TABLE C - Vacuum Forming [arguements gen teow ae uborhains cose specie eqn Ie contr ay have aor eines «9 Inepctonetg eter Rene, When prtorig to aud he ude hl wey moe cong Cate gue, isi repiremert ae ptt previ nppeting cnt ert acti onde. = wens | Sot teat era cannes Son oe entre eency onan = ed Gea rm ca cae | 1 aeteeeninemeeneemesey me fescue cars | £35 jeemeniet sittin, eactonspond an ton hetomac |pstp ant vey Bou can | £39 frwaee tt, tt tna rn ago) Isom Jeep ante te case | Float wnt ane Ice fesse neste cam | 1 tnarteromnt pt tie —_ lessees or EY |ecteieoe: |Starvup, and estan ter a — nt [anna men exw | 135 lent com pocotes just lef praton ere cet | 2 ems te ga) = od re ree fs cant satya ce a ial femme ‘ozo Peres | uOIseA £2109 juowissessy worshs Buyplowy :8S020/q Je/20dS“lr PROCESS TABLE D -Compression Molding ‘arenes gr low a sober ctr pete oer he camry ve anal gute 9 Inpetonti,rtrregutcie ete, Whe prog hf ah ao al eyo efoming alone eqns, “remem ecient se eta. sie veering nk ijt wl codons lees aro (inti Fet Oa epemtrcrpnndietn, [ecfiemrn a exon ike ec a ieeememes 239 | For rubs RPM, embers, atv [ee | feemeemennntnnennenis fae haw 7 | f Soe lone lero ae ou fener aaeane ns ria trp aa [evans we manaty frocves i a | 2h ezensterene ion. met nC wnt [reams ' B1GEL SSBI04q Bupjoy uojssesduioa _SOURUPRE 9e0G TEND OL, = 3 s juoulssessy we}sks Bupjoy :ss2201¢ 12;20ds. ‘rioze0 panes) €2-109“8h PROCESS TABLE D- Compression Molding [axrmuremens en now a strato enone spect esemere [me ester may av eons queers 2 pect treet acu, ee, When pong Job hh or hl vty er canon ctor eget rina equrent lt roe upto Ati conn ttn corenail tome | Sse caaporprecne aps "Wns ot ont enti rcetey —| sence aimee Ramones | Atlin | mentum | Atomon | na oe | 2h mesunancoom caer orton pronriton ven et ns 22 ipam th 12 satceanennnang oerarevoconeaen tet — In ertcatnt os | 2) etter ceoremrom. |e ois | 251 foronewetonctmatonorsic) i ferent ttre ine) or | [iiiitertansaere tons lente eve w|i pee = w|i fpeonenmncnennneae fo — a en mo heron a fn a oe |e fenmonroemnwn - = oo |S bene L = "PiOZI60 Panes | UOIRGA juouissessy weshs BuIplow :ssea014 [2/90dS. Se as OAD ML <= OVIV £2109“6 PROCESS TABLE D - Compression Molding [at mont hn blow ar suborder garements |r comamar may hv ona equrmts¢g mpacton eg ser reece Whe pertain eo athe aor shal arty mel conforming ctor gro ‘trou remorse et pro sapoting ears oy al condos. = earn tame | Syn cn trocar Sane ‘pect conte oot Fregseney 7 nenensenet | Acuaonaion | tina acorns | Acitcoaon | Oe! a a fn feet ser sce ot | it fomwe fm [erty senate = | ah penne f= —— SS = OvIV Juewissessy weyshs Bulpjoy :s8020/q Je/eds. 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ASTM: American Society for Testing and Materials. Back Pressure: The resistance of the molten plastic material to forward flow. In molding, back pressure increases the temperature of the melt, and contributes to better mixing of colors and homogeneity of the material. However, as back pressure increases, so does cycle time. Barrel: The section of a molding machine that contains the feed screw, also the section where resin heating and mixing occurs, Blister: An imperfection on the surface of a plastic article caused by a pocket of air or gas beneath the surface, Blow Molding: Method of fabrication in which a warm plastic hollow tube is placed between the two halves of a mold cavity and forced to assume the shape of that mold cavity by use of internal pressure, Cavity: A depression, or a set of matching depressions, surfaces of the molded articles. a plastics-forming mold which forms the outer Charge: The measurement or weight of material necessary to fill a mold during one cycle. Clamping Pressure: The pressure applied to the mold to keep it closed during the molding cycle. Closed-loop Control: System for monitoring and automatically adjusting injection molding process conditions such as temperature, pressure and time, The automatic changes keep part production within preset tolerances. Compound: A mixture of resin(s) and additives usually formed in a separate machine downstream from the primary reactor. Compounding: The process required to mix polymer(s) with all ofthe additives that are necessary to provide the end user with a finished grade with suitable properties. ‘Compression Molding: A method of molding in which the molding material, generally preheated, is placed in an open heated mold cavity, the mold is closed with a top force, pressure is applied to force the material into contact with all mold areas. Cooling time: The elapsed time required for the melt to reach its Vicat softening temperature. Crack/Splits/Chips: A physical separation or tearing of the part CSA: Canadian Standards Association, Cycle Time: The position/state. 1e required by an injection molding system to mold a part and return to its original Cycle: Complete, repeating sequence of operations for injection molding a part.AIAG cosas strona ein oS ‘The Catlyet for Pek Pertarmance’ Version 1, Issued 08/2014 Density: Mass per unit volume of a substance. Drying: The removal of moisture from the resin pellets by exposure to certain time and temperature. All Hydroscopic Material must be dried prior to molding, Extrusion: The process of forming continuous shapes by forcing a molten plastic material through a die. Fiber: This term usually refers to thin fibers of glass which are used to reinforce materials. One-inch long fibers are occasionally used, but the more commonly used fiver lengths are 1/2” and 1/4", or ess. Fill Time (also known as Injection): Time required to fil he cavity or mold. Fill: The packing of the cavity or cavities of the mold as required to give a complete part or parts that are free of flash and porosity. Finish: The surface texture and appearance of a finished article. Flash: Any excess material that is formed with and attached to the component along a seam or mold parting line. Flow Rate: The volume of material passing a fixed point per unit time. Gate: The channel through which the motten resin flows into the cavity Injection Molding: The method of forming objects from granular or powdered plastics, most often of the thermoplastic type, in which the materials is fed from a hopper to a heated chamber in which itis softened, after which a ram or screw forces the material into a mold. Pressure is maintained until the ‘mass has hardened sufficiently for removal from the mold, Insert Molding: The process of molding plastic around another object that has been placed into the mold cavity before the injection of molten resin. Knit Lines: Where melted material flows together to form a line or lines that may cause weakening or breaking of the component. Lubricant: Internal lubricants, without affecting the fusion properties of a compound, promote resin flow, External lubricants promote release from metals which aids in the smooth flow of melt over die surfaces. Melt Flow: Rate of extrusion of molten resin through a die of specified length and diameter. The conditions of the test (e.g. temperature and load) should be given. ‘Mold (n): A hollow form or matrix into which a plastic material is placed and whic! its final shape as a finished article. parts to the material ‘Mold (v): To impart shape to a plastic mass by means of a confining cavity or matrix. Mold Release: In injection molding, a lubricant used to coat the surface of the mold to enhance ejection of the molded article or prevent it from sticking to the tool Mold Temperature: The temperature at which the mold is maintained. Often the most important benefit of raising mold temperature is that it allows a slower injection rate without the plastic getting too cold. Mold-Temperature-Control Unit: Auxiliary equipment used to control mold temperature. Some units can both heat and cool the mold. Others, called chillers, only cool the mold. 63--64- = AIAG 2 Version 1 lssued 03/2014 “The Catalyst for Pek Partormance™ Nozzle: Hollow metal hose screwed into the extrusion end of the heating cylinder of an injection machine designed to form a seal under pressure between the cylinder and the mold, Pellets: Tablets or granules of uniform size, consisting of resins or mixtures of resins with compounding ‘additives which have been prepared for molding operations by extrusion and chopping into short segments. Pigment (also known as Colorant, Color Concentrate): A plastic compound which contains a high percentage of pigment, to be blended in appropriate amounts with the base resin so that the correct final color is achieved. Preform: A plastic pre- shaped part produced by injection molding systems in the first step of a two-stage injection molding and blow molding process used to produce bottles or containers. The preform is. subsequently re-heated and stretch blown through a biow molding process into the fina container shape. Purging: In extrusion or injection molding, the cleaning of one color or type of material from the machine by forcing it out with the new color or material to be used in subsequent production, or with another compatible purging material. Recovery Time: The length of time for the screw to rotate, create a shot, and retum to original position. Regrind: Waste material such as sprues, runners, excess parison material and reject parts from injection molding, blow molding and extrusion, which has been reclaimed by shredding or granulating. Regrind is usually mixed with virgin compound at a predetermined percentage for remolding, Resin (Synthetic): The term is use to designate any polymer that is a basic materi for plastics. Robot: Automated devices for removing parts upon ejection from an open mold rather than letting the parts drop. Also see parts picker. Robots also can perform secondary functions, such as inspection, degating, precise placement of parts on a conveyor, etc. ‘Trap Points: Areas in containers (baskets, fixtures, shipping boxes, etc.) or any equipment that may inadvertently retain parts, allowing the potential for parts to be mixed between batches. Short Shot (also known as Non-Fill: Failure to completely fl the mold or cavities of the mold. Edges may appear melted. ‘Shrinkage: Contraction upon cooling of all or areas of the part. Shrinkage occurs less in disorientated material and more across chains of molecules than along their lengths. Lower pack areas have lower areas of orientation and shrinkage. ‘Sink Mark: Depressions in the surface of a molded part caused by local internal shrinkage after the gate seals. Sink is most common in thick sections of a part or where features such as ribs or bosses intersect avisual surface. ‘SMC (Sheet Molding Compound): A ready to use glass fiber reinforced polyester material primarily Used in compression molding. Specific Gravity: The ratio of the density of a material as compared to the density of water at standard ‘atmospheric pressure (1 ATM) and room temperature (73F), ‘Splay Marks: Scan or surface defects on molded part caused by abnormal racing of the mett in the moldAIAG» spel Process: dng Systm Sent The Catalyst or Pak Prermance™ Version 7, Issued 0372014 Tensile Strength: The maximum tensile stress sustained by the specimen during a tension test. ‘Thermoset: A polymer that imeversibly cures. Once hardened a thermoset resin cannot be reheated and, melted to be shaped differently ‘Thermo Plastic: A polymer that becomes pliable and moldable above a specific temperature, and returns toa solid state upon cooling. ‘Transfer Molding: A process of forming articles by fusing a plastic material in a chamber then forcing the whole mass into a hot mold to solidity Vacuum Forming: A process whereby a heated plastic sheet is drawn against a mold surface by evacuating the air between it and the mold Vestige: A visible mark created by the gate. iscosity: Resistance to flow of a liquid. Void: An unfilled space within a solid material Weld Line: Where melted material flows together during molding to form a visible line or lines on a finished part that may cause weakening or breaking of the component. 65°-66- ae AIAG 2 Version 1, lesued 03/2014 “The Cotter Pek Porton” [MAINTENANCE REQUEST FORM Name of Submitter: Date: Company: Company Address: Phone: Fax: E.me RNa sou Page Number of Change: Document Currently Reads: Recommended Changes/Should Read: Reason for Change (Use additional she Signature of Submitter: PISS aa) Manager's Recommendation: Final Disposition: Comments: Telephone: (248) 358-3570 + Fax: (248) 358-3253, eMail: [email protected] Web: www.aiag.org