CQI-12

Special Process: Coating System Assessment

Version 1 Issued 8/07

Special Process: Coating System Assessment

Facility Name:
Address:

Phone Number: Type(s) of Coating Processes at this Facility:

Fax Number: Process Table A
Aqueous Cleaning
Number of Coating Employees at this Facility:? Process Table B
Mechanical Cleaning
Captive Coater (Y/N): Process Table C
Commercial Coater (Y/N): Phosphating
Process Table D
Date of Assessment: Powder Coating
Process Table E
Date of Previous Assessment: Electrocoat
Process Table F
Spray
Process Table G
Dip/Spin
Process Table H
Autophoretic
Process Table I
Convective Cure
Process Table J
Equipment

Current Quality Certification(s):

Date of Re-assessment (if necessary):

Personnel Contacted:
Name: Title: Phone: Email:

Auditors/Assesors:
Name: Company: Phone: Email:
Zhiliang.Hong internal Auditor 0512-68057617 [email protected]

Number of "Not Satisfactory" Findings:

0
Number of "Needs Immediate Action" Findings:

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

0
 CQI-12
Special Process: Coating System Assessment (General Facility Overview)
Special Process: Coating System Assessment
Version 1 Issued 8/07

Assessment
Needs
Question Not
Question Requirements and Guidance Objective Evidence N/A Satisfactory Immediate
Number Satisfactory
Action
Section 1 - Management Responsibility and Quality Planning

To ensure readily available expertise, there shall be a dedicated

and qualified coating person on the 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
Is there a dedicated and including chemical and coating knowledge. The qualifications shall
qualified coating person on- include a minimum of 5 years experience in coating operation or a
1.1
site? combination of a minimum of 5 years of formal chemical education
是否有专门的和有资质的喷涂人员在喷涂线 and coating experience.
为了确保能够随时得到专业指导，必须有专门的，具有相关资格的电镀人
员在场。此人必须是全职员工，其职务必须在企业组织结构中有所反映。职责描述中必须包括确认该职位所需资历
，包括化学和电镀知识。职业资格应该包括具有喷涂５年以上工作经验，或化学／化工工程专业教育与喷涂工作相
加，５年以上工作经验。

The organization shall incorporate a documented advanced quality

planning procedure. 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
Does the coater perform customer, no process changes are allowed unless approved by the
1.2 advanced quality planning? customer. The coater shall contact the customer when clarification
喷涂厂是否进行先期质量策划？ of process changes is required. This clarification of process
changes shall be documented. 企业必须形成
一项正式的先期质量计划程序。必须进行可行性的研究，并且在每个零部件上达成一致意见。相同的部件可以组成
一个系列，由企业来界定。在零部件批准过程被客户认可后，除非经客户批准，不然则不得擅自改动流程。喷涂厂
必须与客户联系，对流程的改变进行说明。流程改变的说明必须记录在案。

The organization shall incorporate the use of a documented Failure

Mode and Effects Analysis (FMEA) procedure 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. In any case, they
Are the coater's FMEA's up to
shall address all process steps from part receipt to part shipment
date and reflecting current
and all key coating process parameters as defined by the
1.3 processing?
organization. A cross-functional team shall be used in the
喷涂的FMEA是否更新并反映在 development of the FMEA. All special characteristics, as defined
制程 by the organization and its customers, shall be identified, defined,
and addressed in the FMEA. 企业必须使用正规的失效模式和后果分析程序，并确保ＦＭＥＡ
Ｓ能够反映最新的零部件质量情况。必须对每个零部件或系列都编写ＦＭＥＡ，如果有具体的流程，则每一步都要
编写。任何情况下，都必须处理从零部件接收到装运的每一步盒企业所界定的所有关键喷涂流程参数。必须组成一
个综合职能团队来开发ＦＭＥＡ。所有企业定义或客户规定的特性必须在ＦＭＥＡ中进行确认、定义和处理。
 CQI-12
Special Process: Coating System Assessment
Special Process: Coating System Assessment (General Facility Overview) Version 1 Issued 8/07

Assessment
Needs
Question Not
Question Requirements and Guidance Objective Evidence N/A Satisfactory Immediate
Number Satisfactory
Action

The organization shall incorporate the use of a documented Control

Plan procedure and ensure the Control Plans are updated to reflect
current controls. The Control Plans shall be written for each part or
part family or they may be process-specific and written for each
process. In any case, they shall address all process steps from part
receipt to part shipment and identify all equipment used and all key
coating process parameters as defined by the organization. A
cross-functional team, including a production operator, shall be
Are finish process control used in the development of Control Plans, which shall be consistent
plans up to date and reflecting with all associated documentation such as work instructions, shop
1.4 current processing? travelers(车间布置图), and FMEAs. All special characteristics, as Y
控制计划是否最新并反映实际的制程? defined by the organization and its customers, shall be identified,
(最新的生产计划是否能如实反映我们的制程) defined, and addressed in the Control Plans. Sample sizes and
frequencies for evaluation of process and product characteristics
shall also be addressed consistent with the minimum requirements
listed in the Process Tables.企业必须使用正规的控制计划程序，确保其被更新，能够反映现行
的控制，必须为每个零部件或系统都制定控制计划。在任何情况下，企业必须处理所有流程步骤，从零部件接收到
装运，确认企业已对所有使用的设备和所有关键喷涂流程参数进行定义，必须组成一个综合职能团队，包括一名生
产操作员，来开发控制计划，该控制计划必须符合所有相关文件，比如工作说明，车间导示和ＦＭＥＡ。所有由企
业或客户定义的特性，必须在控制计划中进行中进行确定、定义和处理。评估过程和产品特性的取样数量及频率也
必须至少按流程表要求来处理。

To ensure all customer requirements are both understood and

satisfied, the organization shall have all related coating and
customer referenced standards and specifications available for use
and a method to ensure that they are current. Such standards and
specifications include, but are not limited to, those relevant
documents published by SAE, AIAG, ASTM, General Motors, Ford,
and DaimlerChrysler. The organization shall have a process to
ensure the timely review, distribution, and implementation of all
Are all coating related and customer and industry engineering standards and specifications
referenced specifications and changes based on customer-required schedule. This process
current and available? For shall be executed as soon as possible and shall not exceed two
example: SAE, AIAG, ASTM, weeks. The organization shall document this process of review and
1.5 General Motors, Ford, and implementation, and it shall address how customer and industry
DaimlerChrysler. documents are obtained, how they are maintained within the
是否所有与喷涂相关的参考细则都是最新的，并 organization, how the current status is established, and how the
可以获得？比如：SAE,AIAG,ASTM,通 relevant information is cascaded to the shop floor within the two-
用，福特和克莱斯勒。 week period. The organization shall identify who is responsible for
performing these tasks. 为了保证所有客户要求都能被完全理解并得到满足，企业必须将所有
相关的喷涂和客户参考标准与具体要求联系起来使用，并确保这些信息是最新的。这些标准和要求中包括由
SAE,AIAG,ASTM,通用，福特和克莱斯勒发行的文件，但不局限于以上这些结构。企业必须制定流程
，定期评审，分发和执行所有客户／行业标准和规范以及基于客户要求的变更。该流程必须立即执行，不得超过两
周。企业必须记录检查和执行过程，并且必须落实如何获取客户和行业文件，如何在企业中保持，如何建立现状，
以及如何将这些信息在两周内传达到车间等问题。企业还必须确定由谁来负责这些工作。
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07
Special Process: Coating System Assessment (General Facility Overview)

Assessment
Needs
Question Not
Question Requirements and Guidance Objective Evidence N/A Satisfactory Immediate
Number Satisfactory
Action

The coater shall have written process specifications for all active
processes and identify all steps of the process including relevant
operating parameters. Examples of operating parameters include
process temperatures, cycle times, load rates, rectifier settings, etc.
Such parameters shall not only be defined, they shall have
Is there a written process
operating tolerances as defined by the organization in order to
specification for all active
1.6 maintain process control. All active processes should have a
processes? 所有现行的工序是否都有书面 written process specification. These process specifications may
工序规范？ take the form of work instructions, job card, computer-based
recipes, or other similar documents.喷涂厂必须有针对所有项的工序具体的书面规范，并
明确所有工序的步骤包括相关操作参数。操作参数如温度、周期、负载率、整流器设置，等。这些参数必须不仅只
被定义，而且必须由企业规定允许操作范围，以保持对该工序的控制。所有的现行工序必须有书面的工序规范，这
些规范应该来自于操作指导，工作说明，电脑程序或其他相似的文件。

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 rebuild of any equipment.
The organization shall define what constitutes a major rebuild.
Initial product capability studies shall be conducted for all coating
processes per line as defined in scope of work and in accordance
Has a valid product capability with customer requirements. Capability study techniques shall be
study been performed initially appropriate for the coating product characteristics, e.g., coating
1.7 and after process change?在新 thickness, corrosion resistance, etc.. Any specific customer
产品导入或制程变更时是否有进行产品的初始化能 requirements shall be met. In the absence of customer
力研究？ requirements, the organization shall establish acceptable ranges for
measures of capability. An action plan shall exist to address the
steps to be followed in case capability indices fall outside customer
requirements or established ranges.为了证明每道工序都能生产出合格产品的能力，该组
织应当在产品批准前、任何制程设备移动后、任何设备在较大的维修后进行初始化能力研究。组织应界定什么是较
大的维修。在定义的工作范围内和根据客户的要求为每条喷涂线的制程进行初始化能力研究。能力的研究，应对喷
涂产品特性来进行，例如，涂层厚度，耐腐蚀性等。任何特殊客户的要求应得到满足。在缺乏客户要求的情况下，
企业必须建立可行的性能检测范围。在初始化能力未达到客户要求或没有达到接受范围时应有整改措施。
 CQI-12
Special Process: Coating System Assessment
Special Process: Coating System Assessment (General Facility Overview) Version 1 Issued 8/07

Assessment
Needs
Question Not
Question Requirements and Guidance Objective Evidence N/A Satisfactory Immediate
Number Satisfactory
Action

The analysis of products and processes over time can yield vital
information for defect prevention efforts. The organization shall
Does the coater collect and have a system to collect, analyze, and react to product or process
analyze data over time, and data over time. Methods of analysis shall include ongoing trend or
1.8 react to this data? historical data analysis of special product or process parameters.
是否喷涂线有长期保持收集和分析数据，并对这些 The organization shall determine which parameters to include in
数据作出调整？ such analysis对产品和工序进行持续分析，为故障预防提供重要信息，企业必须有相应的系统，持续不断
地采集、分析、并对产品和流程数据作出反应。分析方法必须包括对特殊产品或流程参数运行趋势或历史数据的分
析。企业必须决定应对哪些参数进行这类分析。

Are internal assessments

The organization shall conduct internal assessments on an annual
being completed on an annual
basis, at a minimum, using the AIAG CSA. Concerns shall be
1.9 basis, at a minimum,
addressed in a timely manner.企业必须根据ＡＩＡＧ的ＣＳＡ每年进行一次内部评估。对发
incorporating AIAG CSA?内部评
现的问题应及时进行处理。
估是否根据ＡＩＡＧ的ＣＳＡ每年进行一次。

The quality management system shall include a documented

process for reprocessing that shall include authorization from 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
Is there a system in place to reprocessing activity shall require a new processing control sheet
authorize reprocessing and is issued by qualified technical personnel denoting the necessary
1.10
it documented?是否有一个系统批准再加 coating modifications. Records shall clearly indicate when and how
工，并对其进行记录？ any material has been reprocessed. The Quality Manager or a
designee shall authorize the release of reprocessed product.质量管理系
统必须包括一个正规的再加工流程，该流程必须经指定人员认可。再加工流程必须对再加工流程允许的或不允许的
产品属性进行描述。所有再加工处理必须要求一份新的流程控制表，该表是由具有资质的技术人员选择的必要喷涂
修整。再加工记录必须标明材料在何时，使用何种方式进行再加工。质量经历或指定的人员必须批准对再加工产品
的发放。

The quality management system shall include a process for

Does the Quality Department
documenting, reviewing, and addressing customer concerns and
review, address, and
any other concerns internal to the organization. A disciplined
1.11 document customer and
problem-solving approach shall be used.质量管理系统必须包括一个正规化流程，检查
internal concerns?质量部门是否检查
流程和处理客户及其他内部意见的流程。必须使用纪律严明的解决问题方法。(公司应该对处理客户投诉以及内部
、处理和记录客户意见和内部意见？
发现的一些问题进行流程的规定)

The coater shall define a process for continual improvement for

Is there a continual each coating process identified in the scope of the CSA. The
improvement plan applicable process shall be designed to bring about continual improvement in
to each process defined in the quality and productivity. Identified actions shall be prioritized and
1.12 shall include timing (estimated completion dates). The organization
scope of the assessment?
每个评估范围内确定流程是否有持续可行的改进计 shall show evidence of program effectiveness.喷涂工必须确定一个对每个在
划？ CSA范围内的喷涂流程进行持续改善的流程。该流程必须能够在质量和产量上起到完善作用。必须明确各项措
施的先后次序，必须包括时间限制（估计完成日期）。企业必须证明其计划的有效性。
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Special Process: Coating System Assessment (General Facility Overview)

Assessment
Needs
Question Not
Question Requirements and Guidance Objective Evidence N/A Satisfactory Immediate
Number Satisfactory
Action

Does the Quality Manager or

designee authorize the The Quality Manager or designee is responsible for authorizing and
1.13 disposition of material from documenting appropriate personnel to disposition quarantine
quarantine status? 质量经理或专员是 material.质量经理或指定人员负责授权和证明由某个合适的人员来处理被隔离的材料。
否批准对隔离状态物料的处理？

There shall be procedures or work instructions available to coating

personnel covering the coating process. These procedures or work
instructions shall include methods of addressing potential
Are there procedures or work
emergencies (such as power failure), equipment start-up,
instructions available to
equipment shut-down, product segregation (See 2.8), product
1.14 coating personnel that define
inspection, and general operating procedures. These procedures or
the coating process?是否有程序或作
work instructions shall be accessible to shop floor personnel.应当有程序
业指导提供给喷涂人员喷涂过程的定义？
或作业指导书提供给喷涂人员喷涂工艺。这些程序或作业指导书应包括解决潜在的紧急情况，（如电源故障），设
备启动，设备关机，产品隔离（见2.8），产品检验，和一般生产程序。车间人员应较方便的得到这些程序或作
业指导书。

The organization shall provide employee training for all coating

operations. All employees, including backup and temporary
employees, shall be trained. Documented evidence shall be
maintained showing the employees trained and the evidence shall
Is management providing
include an assessment of the effectiveness of the training.
1.15 employee training for coating?
Management shall define the qualification requirements for each
管理部门是否提供有关喷涂方面的员工培训？ function, and ongoing or follow-up training shall also be addressed.
企业必须为员工提供所有喷涂作业的培训。所有的员工，必须后备和临时工，都必须接受培训。必须保留员工培训
的相关证明，这些证明必须包括一份培训效果评估。管理部门必须对每个广为的资质要求进行界定。同时落实正在
进行的或将要进行的培训。

Is there a responsibility matrix The organization shall maintain a responsibility matrix identifying all
to ensure that all key key management and supervisory functions and the qualified
management and supervisory personnel who may perform such functions. It shall identify both
1.16 functions are performed by primary and secondary (backup) personnel for the key functions (as
qualified personnel?是否编制了责任 defined by the organization). This matrix shall be readily available
矩阵，以确保所有的关键管理和监督职能是由相关 to management at all times.组织应保持一份责任矩阵确定的所有关键管理和监督职能和能执行
资质的人员执行？ 的有资质的人员。责任矩阵图应确定的主要和次要（替补）人员。这个矩阵必须随时供管理部门使用。
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Special Process: Coating System Assessment (General Facility Overview)

Assessment
Needs
Question Not
Question Requirements and Guidance Objective Evidence N/A Satisfactory Immediate
Number Satisfactory
Action

The organization shall have a documented preventive maintenance

program for key process equipment (as identified by the
organization). The program shall be a closed-loop process that
tracks maintenance efforts from request to completion to
Is there a preventive
assessment of effectiveness. Equipment operators shall have the
maintenance program? Is
opportunity to report problems, and problems shall also be handled
maintenance data being
in a closed-loop manner. Company data, e.g., downtime, quality
utilized to form a predictive
1.17 rejects, first time-through capability, recurring maintenance work
maintenance program? 是否有一
orders, and operator-reported problems, shall be used to improve
个预防性的维护程序?维护数据是否被用来形成定 the preventive maintenance program. Maintenance data shall be
期的维护计划？ collected and analyzed as part of a predictive maintenance
program.企业必须对重要的工序设备制定正规的定期维护计划。该计划必须是一个双向的流程，从提出请求
到评估完毕，通过不断努力评估其有效性。设备操作人员必须有机会反应问题，对所反映的问题则必须作出回应。
公司数据，例如：停机时间，质量退回，一次通过率，反复维护工作要求，以及操作人员报告问题，必须用以完善
定期维护计划。维护数据必须被收集和分析，作为定期维护计划的一部分。

Has the coater developed a

The coater shall develop and maintain a critical spare parts list and
critical spare part list, and are
shall ensure the availability of such parts to minimize production
1.18 the parts available to minimize
disruptions.为了减少喷涂线生产的中断，喷涂线的维护和保养需要一份关键零部件清单,并应确保此类零件
production disruptions?喷涂是否有
的有效性。
一份主要零部件的清单,用来减少生产中断?

Section 2 - Floor and Material Handling Responsibility（

Does the facility ensure that

the data entered in the
Documented processes and evidence of compliance shall exist,
receiving system matches the
e.g., shop travelers, work orders, etc. The facility shall have a
2.1 information on the customer's
detailed process in place to resolve receiving discrepancies.必须有正规
shipping documents?工厂是否能够
的流程和证明，如：车间导示，工作规章，等。工厂必须有适当的详细流程来解决接收的差异。
保证输入到接收系统的数据能够与客户装运信息所
匹配？

Procedures for part and container identification help to avoid

incorrect processing or mixing of lots. Appropriate location and
staging within the facility also help to ensure that orders are not
shipped until all required operations are performed. Customer
Is product clearly identified
product shall be clearly identified and staged throughout the coating
and staged throughout the
2.2 process. Non-coated, in-process, and finished product shall be
coating process?产品在喷涂制程的各 properly segregated and identified. All material shall be staged in a
个阶段能清楚地识别? dedicated and clearly defined area. 零部件和装运容器的识别程序，可以帮助避免不正确
的流程和货物批次混淆。适当的位置和配置实施确保订单在所有要求的操作完成后进行发货。客户的产品必须在喷
涂过程中进行明确区分和配置。未喷涂的，在制品和成品必须适当分隔和识别。所有材料必须分配到专门的，明确
分隔的区域。
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Special Process: Coating System Assessment (General Facility Overview)

Assessment
Needs
Question Not
Question Requirements and Guidance Objective Evidence N/A Satisfactory Immediate
Number Satisfactory
Action

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

Is lot traceability and integrity
The descipline of precisely identifying lots and linking all pertinent
maintained throughout all
2.3 information to them enhances the ability to do root cause analysis
processes?一批产品是否在所有流程中都保
and continual improvement.发出的货物必须能追溯到进厂的货物。及时识别货物，并且联系所
持追溯性和完整性?
有相关货物信息的规定，增强了进行根据问题分析和持续改进的能力。

The control of suspect or non-conforming product is necessary to

prevent inadvertent shipment or contamination of other lots.
Procedures shall be adequate to prevent movement of non-
Are procedures adequate to
conforming product into the production system. Procedures shall
prevent movement of non-
exist addressing proper disposition, product identification and
2.4 conforming product into the
tracking of material flow in and out of hold area. Non-conforming
production system? 是否程序是否可
hold area shall be clearly designated to maintain segregation of
以避免不合格品流入的合格产品中? such material.控制待定或不合格品是必须的,以防止疏忽装运或混入其他批次。必须有适当的程序防止不
合格品的混入到正常的生产中。程序应放置在合适的位置，在存放区域识别产品和跟踪物料进出。不合格存放区必
须被清楚地标示，以保持对这种材料的隔离。

Is there a system to identify

trap points in the entire
process to reduce risk of The coater shall have documented procedures to identify and
mixed parts (inappropriate, monitor trap points for each process/equipment. Monitoring of
2.5 unfinished or improperly potential trap points shall occur for every part changeover.喷涂厂必须有正
coated parts)?是否有一个系统可以识别 规的流程来识别和检测每个工序设备的漏洞。必须在每个部件转换时对潜在漏洞进行监测。
漏洞，以减少整个流程中混料的风险(不良，未喷涂
的,或未正确喷涂零部件）?

Containers handling customer product shall be free of inappropriate

material. After emptying and before re-using containers, containers
shall be inspected to ensure that all parts and inappropriate
Are containers free of material have been removed. The source of inappropriate material
2.6 inappropriate material?包装容器中 shall be identified and addressed. This is to ensure that no
是否不存在不适合的物料? nonconforming coated parts or inappropriate material contaminate
the finished lot.用装载容器包装客户产品时必须避免使用不适当的材料。在将包装容器腾空倒再次使用
之间，包装容器必须接受检查，确保所有零部件和不适当的材料都被移除。不适当的材料必须加以识别和处理。这
样可以确保没有不合格零部件或不明材料污染完成品货物。

Loading parameters shall be specified, documented and controlled.

Examples include parts per rack and load size.
Is part loading specified,
2.7 documented and controlled?零 Refer to Process Tables for frequency of checks. 装运参数必须被详列,证明
部件装运是否有明确的要求，记录和控制? 和控制。样品包括每个架子上的零部件和装运规格。

涉及到的Process Tables频率的检查。
 CQI-12
Special Process: Coating System Assessment
Special Process: Coating System Assessment (General Facility Overview) Version 1 Issued 8/07

Assessment
Needs
Question Not
Question Requirements and Guidance Objective Evidence N/A Satisfactory Immediate
Number Satisfactory
Action

Unplanned or emergency downtime greatly raises the risk of

improper processing. Operators shall be trained in material
Are operators trained in handling, containment action, and product segregation in the event
material handling, of an equipment emergency including power failure. Training shall
containment action and be documented. Work instructions specifically addressing potential
product segregation in the types of equipment emergencies and failures shall be accessible to
2.8 event of an equipment and understood by equipment operators. These instructions shall
emergency including power address containment/reaction plans related to all elements of the
failure? 操作人员是否进行过物料处理，封锁 process. Evidence shall exist showing disposition and traceability of
行动和产品隔离的培训，以在设备出现紧急情况时 affected product.不在计划中或紧急的停机很大程度上提高了不适当流程的风险。操作人员必须接受物
（包括停电）作出反应。 料装运、封锁行动和产品隔离的培训，以防设备发生紧急情况，包括停电。解决设备潜在故障和紧急情况的工作说
明细则必须易于设备操作人员理解和接受。这些指南必须落实所有与流程要素相关的封锁/反应计划，必须证明对
受到停机影响的产品进行处理和追溯。

Is the handling, storage and The coater's loading/unloading systems, in-process handling and
packaging adequate to shipping process shall be assessed for risk of part damage or other
2.9
preserve product quality? 是否在 quailty concerns.喷涂者在装卸系统、生产中的搬运和运输过程中应对产品损坏或其它的质量问题进行
搬运、贮存、包装足以保护产品的质量? 风险的评估。

Plant cleanliness, housekeeping, environmental, and working

conditions shall be conducive to controlling and improving quality.
Are plant cleanliness,
The coater should evaluate such conditions and their effect on
housekeeping, environmental
quality. A housekeeping policy shall be clearly defined and
and working conditions
2.10 executed. The facility shall be reviewed for the following items:
conducive to control and
loose parts on floor; spillage around tanks; overall plant lighting;
improved quality?车间的干净、环境和
fumes etc.车间的整洁、环境和工作条件的,应当有利于控制和改善产品质量。喷涂者应当在这样的条件和效
工作条件是否有利于控制和改善品质吗?
果下评估对质量的影响。一个整理政策应当明确定义并执行。这个工厂应当对以下事项进行检查:掉落部件在地板
上,漏油，整体工厂照明、废气等。

Process control parameters shall be monitored per frequencies

Are process control
specified in Process Tables. Computer monitoring equipment with
parameters monitored per
alarms and alarm logs satisfy the verification requirement. A
frequencies specified in
2.11 designated floor person shall verify the process parameters, e.g.,
Process Tables? 是否过程控制参数监
by initialing a strip chart or data log. 工艺控制参数应监测过程中每个规定的频率在
测过程中每个规定的频率在Processs
Prcoess Tables中。计算机监控设备带有报警和报警记录满足验证要求。指定车间验证人应证实过程参
Tables吗?
数,例如,最初数据图表或数据的记录。

Are out of control/specification There are documented reaction plans to both out of control and out
parameters reviewed and of tolerance process parameters. There is documented evidence
2.12
reacted to?是否有失去控制/规格参数进行 that reaction plans are followed.对于不受控和超差的参数是否有书面的应对计划？是否有书
了检讨并做出反应? 面的证明表明这些应对计划被实施。

Are In-Process / Final Test

Frequencies performed as In-Process / Final Test Frequencies shall be performed as specified
2.13 specified in Process Tables?是 in Process Tables. Refer to Process Tables在制程/成品测试频率应当按照
否在制程/成品的测试频率按照Process Process Tables执行。参考Process Tables。
tabels规定的执行。
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Special Process: Coating System Assessment (General Facility Overview)

Assessment
Needs
Question Not
Question Requirements and Guidance Objective Evidence N/A Satisfactory Immediate
Number Satisfactory
Action

Test equipment shall be verified/calibrated per applicable customer

specific standard or per an applicable consensus standard, e.g.,
ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be
Is product test equipment internally reviewed, approved and documented.
2.14 verified?
生产测试设备额是否经过认证。 Refer to Process Tables for frequency of checks.
测试设备必须按适用客户特定标准或适当的共同标准，如：
ASTM，SAE，ISO，NIST等进行检验/校准，检验/校准结果必须进行内部审核，批准和文件化。
检查的频率参考Process Tables
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Section 3 - Job Audit - Finished Product Review

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:

Job (Shop) Order or

Related Customer or Internal Actual Condition Pass / Fail /
Question # Job Audit Question Reference Documentation
CSA Question # Requirement (Objective Evidence) N/A
Requirement
N/A

Is contract review and advanced 1.1

quality planning, FMEA, control 1.2
3.1 plans, etc., performed by qualified 1.3
individuals? 有相关资格人员是否进行合同评审，先 1.4
期质量策划，FMEA，控制计划，等？ 1.6

N/A
Does the Coater have the proper
3.2 customer specifications for the 1.5
part?喷涂厂是否拥有有关客户对零部件的具体要求？

Is a shop traveler created to meet

1.6
3.3 customer requirements?是否根据客户的要
2.1
求编制车间导视图？

Is material identification (part

numbers, lot numbers, contract
numbers, etc.) maintained 2.2
3.4 2.3
throughout the coating process?喷涂
2.4
过程中是否保持物料识别（零部件编号，批号，合同号，等
）？

Is there documented evidence of

3.5 Receiving Inspection?是否有文件化的进料检 2.1
查证明？

Are the Loading / Racking 1.6

3.6 requirements identified?是否明确装运/装载 2.7
要求？ 2.9
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Section 3 - Job Audit - Finished Product Review

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:

Job (Shop) Order or

Related Customer or Internal Actual Condition Pass / Fail /
Question # Job Audit Question Reference Documentation
CSA Question # Requirement (Objective Evidence) N/A
Requirement

Is the proper procedure or process

specification used? Refer to
Process Tables for specific 1.5
parameters. List parameters that 1.6
3.7 were verified in this audit in the 2.1
2.11
spaces provided below.是否采用适当的程序
2.13
或工序规范？具体参数参考工序表，列出审核中检查的参数
，填入下列空格内。

gun height枪高

conveyor speed/drying temperature

lacquar viscosity

adjust scale
cross-cut

shade
thickness
gloss
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Section 3 - Job Audit - Finished Product Review

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:

Job (Shop) Order or

Related Customer or Internal Actual Condition Pass / Fail /
Question # Job Audit Question Reference Documentation
CSA Question # Requirement (Objective Evidence) N/A
Requirement

1.5 Each part may have one or more requirements determined by the coating specification. Parts
What are the product inspection
3.8 2.13 must meet each requirement. List each requirement below and validate.
requirements?产品检验的要iu是什么？
2.14 (Listed below are some examples)每个部件都有一个或几个喷涂的规格要求。部件必须满足每个规格。清单要求如下

Requirement: Coating Thickness 要

3.8.1
求：喷涂膜厚
Test Method测试方法:
Test frequency or quantity测试频率或数量
:

Selection of samples样品数量:

Specification规格:
Requirement: Corrosion Resistance
3.8.2 (if applicable) 要求：耐腐蚀测试（假如
可以的话）.
Test Method(s)测试方法:
Test frequency or quantity测量频率或数量
:
Selection of samples样品数量:
Specification规格:
Requirement: Hydrogen
Embrittlement Relief (if applicable)要
3.8.3 求：

Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
3.8.4 Requirement: Adhesion要求粘度
Test Method(s):
Test frequency or quantity:
Selection of samples:
Specification:
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Section 3 - Job Audit - Finished Product Review

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:

Job (Shop) Order or

Related Customer or Internal Actual Condition Pass / Fail /
Question # Job Audit Question Reference Documentation
CSA Question # Requirement (Objective Evidence) N/A
Requirement
3.8.5 Requirement: Cure要求：固化
Test Method:
Test frequency or quantity:
Selection of samples:
Specification
Requirement: Torque Tension (if
3.8.6
applicable)要求：扭力（假如可能）
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Section 3 - Job Audit - Finished Product Review

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:

Job (Shop) Order or

Related Customer or Internal Actual Condition Pass / Fail /
Question # Job Audit Question Reference Documentation
CSA Question # Requirement (Objective Evidence) N/A
Requirement
Requirement: Appearance
3.8.7
(Decorative)要求：外观（装饰件）
Test Method:
Test frequency or quantity:
Selection of samples:
Specification
Requirement: Dimensional (if
3.8.8
applicable)尺寸（假如可能）
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
Requirement: Color and Gloss
3.8.9
(Decorative)要求颜色和光泽（装饰件）
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
Requirement: Customer Specific要求
3.8.10
：客户的特殊特性
Test Method(s):
Test frequency or quantity:
Selection of samples:
Specification:
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Section 3 - Job Audit - Finished Product Review

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:

Job (Shop) Order or

Related Customer or Internal Actual Condition Pass / Fail /
Question # Job Audit Question Reference Documentation
CSA Question # Requirement (Objective Evidence) N/A
Requirement
Operator or Inspector Responsibilities运营和检验要求
1.4
1.6
Were appropriate process steps
3.9 2.2
signed off? 相应的工序步骤是否被批准？
2.3
2.11
Were all inspection steps, as
documented in the control plan 1.2
3.10
performed?控制计划中规定的所有检查步骤是否被 1.4
执行？

Were steps/operations performed

1.2
that were not documented in the
3.11 1.4
control plan? 有没有执行控制计划中没有的步
1.6
骤/操作？

1.2
If additional steps were performed, 1.4
3.12 were they authorized?如果有另外的步骤被执 1.6
行，这些步骤是否被授权？ 1.10
1.16
Does the governing specification
1.5
3.13 allow reprocessing or rework?是否控制
1.10
规格中允许返工或再喷。

If the order was certified, did the

certification accurately reflect the 2.11
3.14
process performed?如果订单被确认，确认书 2.13
是否准确反映其操作流程？

Was the certification signed by an

3.15 authorized individual?确认书的签署人是否被
1.16
授权？
Not allow inappropriate
Are the parts and containers free of
objects or contamination.
inappropriate objects or
3.16 2.6
contamination?零部件和装载容器是否与外来物体
或污染物隔绝？
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

Section 3 - Job Audit - Finished Product Review

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:

Job (Shop) Order or

Related Customer or Internal Actual Condition Pass / Fail /
Question # Job Audit Question Reference Documentation
CSA Question # Requirement (Objective Evidence) N/A
Requirement

Packaging Requirements包装要求

2.6 Every parts must have the

Are packaging requirements
3.17 2.7 standard package information.
identified? 是否有明确的包装要求？
2.9
Not allow mixed parts.
Are parts packaged to minimize
mixed parts (for example, parts 2.6
3.18 packed over height of container)?零 2.7
部件包装是否为了使零部件混杂度最小化（例如：零部件包 2.9
装高度大于装载容器）？

Shipping Requirements运输要求

Were the parts properly identified? 2.3 The parts properly must be
3.19 零部件是否进行适当确认？ identified.
2.9
The containers properly must
2.3
3.20 Were the containers properly be labeled
2.9
labeled?运载容器是否有标签标示？
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE A - Pretreatment (Aqueous)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing
the job audit, the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
AQUEOUS CLEANING PROCESS (Alkaline
1.0
or Acid)
There shall be an incoming part assessment
A1.1 1.4 Per Control Plan Per lot
procedure with criteria.
2.0 Cleaning Bath(s)
The following checks shall be performed
A2.1 2.11
during production:
1.4
Per Control Plan/Log Sheet
A2.2 2.11 Pressure/Agitation Automatic/Manual
(1/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
A2.3 2.11 Temperature Automatic/Manual
(1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log Sheet
A2.4 Time Automatic/Manual
2.11 (1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log Sheet
A2.5 Chemical Concentration Automatic/Manual
2.11 (1/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
A2.6 2.11 Impurity Content (e.g. acid split) Manual
(1/shift minimum)
2.12

A2.7 2.11 There is a dump schedule for cleaning baths. Manual Per Control Plan/Log Sheet
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE A - Pretreatment (Aqueous)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing
the job audit, the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
3.0 Rinse Bath(s)
The following checks shall be performed
A3.1 2.11
during production:
1.4
Per Control Plan/Log Sheet
A3.2 2.11 Pressure/Agitation Automatic/Manual
(1/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
A3.3 2.11 Temperature Automatic/Manual
(1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log Sheet
A3.4 Time Automatic/Manual
2.11 (1/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
A3.5 2.11 Impurity Concentration Manual
(1/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
A3.6 2.11 Overflow Rate Automatic/Manual
(1/shift minimum)
2.12
A3.7 2.11 There is a dump schedule for rinses. Manual Per Control Plan/Log Sheet
There is a visual inspection (e.g. water break)
1.4 Per Control Plan/Log Sheet
A3.8 after each post cleaning rinse bath where Manual
2.11 (1/shift minimum)
possible. (not applicable for bulk)

1.4 There is a final rinse. It shall be monitored for Per Control Plan/Log Sheet
A3.9 Manual
2.11 presence of bacteria. (for plastic substrate) (1/shift minimum)

1.4 For Metals -- Corrosion inhibitor concentration Per Control Plan/Log Sheet
A3.10 Automatic/Manual
2.11 is checked. (If applicable) (1/shift minimum)
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

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, greater frequencies, etc. When
performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related
Item # CSA Category/Process Steps种类/过程步骤 Control控制 Monitoring监测
Question #
1.0 ABRASIVE BLAST PROCESS
There shall be an incoming part assessment Per Control Plan每
B1.1 1.4 Per lot每批
procedure with criteria.应当有进料部件的标准评价程序。 个控制计划

The following checks shall be performed during

B1.2 2.11
production:在生产过程中进行以下检查：

1.4 Per Control Plan/Log

1.6 Automatic/Manual Sheet (1/shift
B1.3 Abrasive media flow 研磨膏的使用
2.11 自动/手动 minimum)每个控制计划/表单记
2.12 录（至少 1/班次）

1.4 Per Control Plan/Log

1.6 Automatic/Manual Sheet (1/shift
B1.4 Nozzle air pressure喷嘴气压
2.11 自动/手动 minimum)每个控制计划/表单记
2.12 录（至少 1/班次）

1.4 Per Control Plan/Log

1.6 Automatic/Manual Sheet (1/shift
B1.5 Dwell time停延时间
2.11 自动/手动 minimum)每个控制计划/表单记
2.12 录（至少 1/班次）

Per Control Plan/Log

1.4
Sheet (2/shift
B1.6 2.11 Dust collector efficiency/air flow灰尘收集器效率/空气流动 Automatic自动
minimum)每个控制计划/表单记
2.12
录（至少 2/班次）

Per Control Plan/Log

1.4
Automatic/Manual Sheet (1/shift
B1.7 2.11 Working mix油漆搅拌
自动/手动 minimum)每个控制计划/表单记
2.12
录（至少 2/班次）

Per Control Plan/Log

1.4 Surface cleanliness is checked after process.预 Sheet (1/shift
B1.8 Manual手动
2.11 处理后表面清洁的检查 minimum)每个控制计划/表单记
录（至少 1/班次）

1.4
Surface profile is checked after process (if
B1.9 2.11 Manual手动 Per lot每批
applicable).预处理后表面外观的检查（假如合适）
2.13
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE C - Pretreatment (Phosphating)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When
performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #

1.0 Conversion Coating

There shall be an incoming part
C1.1 1.4 Per Control Plan Per lot
assessment procedure with criteria.
2.0 Rinse Conditioner (If Applicable)
The following checks shall be performed
C2.1 2.11
during production:
1.4
Per Control Plan/Log
C2.2 2.11 Pressure/Agitation Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log
C2.3 Time Automatic/Manual
2.11 Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
C2.4 2.11 Chemical Concentration Automatic/Manual
Sheet (1/shift minimum)
2.12
There is a dump schedule for rinse Per Chemical
C2.5 2.11 Manual
conditioner. Manufacturer's Guideline
3.0 Conversion Coating Bath
The following checks shall be performed
C3.1 2.11
during production:
1.4
Per Control Plan/Log
C3.2 2.11 Pressure/Agitation Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
C3.3 2.11 Temperature Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log
C3.4 Time Automatic/Manual
2.11 Sheet (1/shift minimum)
2.12
1.4 Chemical Concentration (Free Acid, Total
Per Control Plan/Log
C3.5 2.11 Acid, Iron Content, pH, Accelerator Amount Automatic/Manual
Sheet (2/shift minimum)
2.12 as Applicable)
1.4
Fluoride Ion Concentration (if aluminum is Per Control Plan/Log
C3.6 2.11 Automatic/Manual
being coated) Sheet (2/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log
C3.7 Coating Weight Manual
2.11 Sheet (1/shift minimum)
2.12
1.4
Per customer
C3.8 2.11 Crystal Size (If applicable) Manual
requirement
2.12
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE C - Pretreatment (Phosphating)

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When
performing the job audit, the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #

4.0 Rinse After Phosphate

The following checks shall be performed
C4.1 2.11
during production:

1.4
Impurity Concentration (e.g. Titration, Per Control Plan/Log
C4.2 2.11 Manual
Conductivity) Sheet (1/shift minimum)
2.12

1.4
Per Control Plan/Log
C4.3 2.11 Pressure/Agitation Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log
C4.4 Time Automatic/Manual
2.11 Sheet (1/shift minimum)
2.12

Per Chemical
C4.5 2.11 There is a dump schedule for rinses Manual
Manufacturer's Guideline

5.0 Seal Rinse

The following checks shall be performed
C5.1 2.11
during production:
1.4
Per Control Plan/Log
C5.2 2.11 Pressure/Agitation Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log
C5.3 Time Automatic/Manual
2.11 Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
C5.4 2.11 Chemical Concentration Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
C5.5 2.11 Temperature (If applicable) Automatic/Manual
Sheet (1/shift minimum)
2.12
Per Chemical
C5.6 2.11 There is a dump schedule for seal rinse. Manual
Manufacturer's Guideline
6.0 Dry-Off (If Applicable)
1.4
Air temperature is monitored and Per Control Plan/Log
C6.1 2.11 Automatic
controlled. Sheet (1/shift minimum)
2.12
1.4 There is a procedure to ensure dryness of
C6.2 Visual Each Lot
2.11 parts prior to susequent coating.
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE D - Powder

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.

Related
Category/Process Steps Control Monitoring
CSA Question #
1.0 Powder Paint Application
1.4 Parts are checked exiting dry-off oven for cleanliness and trapped Per Control Plan/Log
D1.1 Manual
2.11 water, prior to entering powder booth. Sheet (1 per hour)
2.0 Powder Booth and Equipment
1.4
Per Control Plan/Log
D2.1 2.11 The temperature of parts entering the coating booth is monitored. Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
1.6
The conveyor is operating at the proper line speed (no abrupt Per Control Plan/Log
D2.2 1.17 Automatic
movement or contact between parts). Sheet (1/shift minimum)
2.11
2.12

1.4
The ground is checked using a 500 volt megohm meter (less than Per Control Plan/Log
D2.3 2.11 Automatic/Manual
1megohm resistance). Sheet (1/shift minimum)
2.12
1.4
1.17 Per Control Plan/Log
D2.4 The air dryer and filter are on main compressed air line. Automatic/Manual
2.11 Sheet (1/shift minimum)
2.12

1.4
1.17 Per Control Plan/Log
D2.5 The booth temperature and humidity are checked. Manual
2.11 Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
D2.6 2.11 The air balance in the powder booth is checked. Manual
Sheet (1/day minimum)
2.12
1.4
1.17 Per Control Plan/Log
D2.7 The rotary seive is clean and operational. Automatic/Manual
2.11 Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
D2.8 2.11 The powder flow on seive is monitored. Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
D2.9 2.11 The vent assist air pressure is checked. Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
D2.10 2.11 The vent on feed hopper is checked. Manual
Sheet (1/shift minimum)
2.12
1.4
1.17 Per Control Plan/Log
D2.11 The reclaim seive is operating properly. Manual
2.11 Sheet (1/shift minimum)
2.12
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE D - Powder

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.

Related
Category/Process Steps Control Monitoring
CSA Question #

1.4
1.17 Per Control Plan/Log
D2.12 All guns are operational and in good repair. Manual
2.11 Sheet (1/shift minimum)
2.12

1.4
1.17 The venturis in the feed pumps and the pick up tubes in the hopper
D2.13 Manual Per PM schedule
2.11 are checked.
2.12
1.4
The feed hoses are checked to ensure that they have no excessive Per Control Plan/Log
D2.14 2.11 Manual
bends and kinks. Sheet (1/day minimum)
2.12
1.4
Per Control Plan/Log
D2.15 2.11 The virgin/reclaim ratio is checked. (feed pressure) Manual
Sheet (1/shift minimum)
2.12
1.4
1.17 The static pressure gauges on primary and final filters are Per Control Plan/Log
D2.16 Manual
2.11 checked. Sheet (1/shift minimum)
2.12
1.4
1.11 Per Control Plan/Log
D2.17 Appearance of parts exiting booth is checked. Manual
2.12 Sheet (1 per hour)
2.13

1.4
Per Control Plan/Log
D2.18 2.11 The powder supply and atomizing air pressure are checked. Manual
Sheet (1/shift minimum)
2.12

3.0 Cure (See Convective Cure Process Table I)

 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE E - Electrocoat

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.0 Pre-Electrocoat Paint Application Part Appearance
1.4 Incoming parts are inspected for cleanliness and/or uniform Per Control Plan/Log
E1.1 Manual
2.11 phosphate coating (when phosphate is used). Sheet (1 per hour)
2.0 Electrocoat Laboratory

E2.1 2.14 Laboratory equipment is calibrated and in good working order. N/A

Laboratory standards and reagents are properly stored, labeled,

E2.2 2.14 N/A
and not expired.

Laboratory records, internal and external, are filed and Per Control Plan/Log
E2.3 2.14 N/A
accessible for review. Sheet (1/shift minimum)
3.0 Electrocoat Tank
1.4
Bath parameters (pH, conductivity, solid content, temperature, Per Control Plan/Log
E3.1 2.11 Automatic/Manual
voltage) are checked and adjusted. Sheet
2.12
1.4
1.6 Per Control Plan/Log
E3.2 Line speed setup is checked. Automatic/Manual
2.11 Sheet
2.12
1.4
E3.3 2.11 Line speed is verified. Manual Once/week minimum
2.12
1.4
There is circulation and it is monitored. (flow meter, pressure Per Control Plan/Log
E3.4 2.11 Automatic/Manual
gage) Sheet (1/shift minimum)
2.12
1.4
Bag filter pressures are monitored. Bags changed when psi Per Control Plan/Log
E3.5 2.11 Automatic/Manual
differential. >5-10 PSI. Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
E3.6 2.11 Flow direction is checked (for monorail system). Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan (1/shift
E3.7 2.11 Flow over the weir is checked. Manual
minimum)
2.12
1.4 Per Control Plan/Log
E3.8 2.11 Bath is checked for microbial contamination. Manual Sheet (1/ per week
2.12 minimum)
1.4
Per Control Plan/Log
E3.9 2.11 Incoming DI / RO water is checked for cleanliness. (conductivity) Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
1.17
E3.10 Paint racks are being maintained. Automatic/Manual As needed
2.11
2.12
1.4
1.17
E3.11 There is a paint rack maintenance schedule. Manual Required
2.11
2.12
1.4
1.17 Required (1/year
E3.12 There is a tank clean up schedule. Manual
2.11 minimum)
2.12
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE E - Electrocoat

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
4.0 Anolyte System
1.4
The anolyte solution is being controlled within the required Per Control Plan/Log
E4.1 2.11 Automatic/Manual
conductivity limits. Sheet (1/shift minimum)
2.12
1.4
The conductivity reading on the anolyte tank has been confirmed Per Control Plan/Log
E4.2 2.11 Automatic/Manual
in the laboratory. Sheet 1 / week
2.12
1.4
Per Control Plan/Log
E4.3 2.11 The pH of the anolyte solution has been checked. Automatic/Manual
Sheet (1 per shift)
2.12
1.4
Per Control Plan/Log
E4.4 2.11 Anodes have been inspected. Manual
Sheet (1 per six months)
2.12
1.4
Per Control Plan/Log
E4.5 2.11 The anolyte solution is being circulated to each cell. Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
E4.6 2.11 Dump and clean schedule for anolyte being maintained. Manual
Sheet
2.12
1.4
Per Control Plan/Log
E4.7 2.11 Amperage draw has been checked on each anode. Automatic/Manual
Sheet
2.12
5.0 Rectifier
1.4
1.6
E5.1 The proper voltage is being used for the load size. Manual per Equip. Mfg.
2.11
2.12
1.4
Per Control Plan/Log
E5.2 2.11 The ramp up time to full voltage has been verified. Automatic/Manual
Sheet (1 per shift)
2.12
There is a safety beacon to alert personnel when system is
E5.3 2.10
energized.
1.4
1.17 The ripple of the rectifier has been checked by an approved Per Control Plan / material
E5.4 Automatic/Manual
2.11 electrician. supplier
2.12
6.0 Rinse System
1.4
Immersion rinse tanks are operating at the proper levels and Per Control Plan/Log
E6.1 2.11 Automatic/Manual
tanks are being agitated correctly. Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
E6.2 2.11 There is sufficient permeate supplied to the rinse. Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
E6.3 2.11 The pH and conductivity of the rinse have been recorded. Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan / material
E6.4 2.11 There is microbial testing of rinses. Manual
supplier
2.12
1.4
The ultrafilters are operating at proper pressures and bag filters Per Control Plan/Log
E6.5 2.11 Automatic/Manual
are being used. What size bags? Sheet (1/shift minimum)
2.12
1.4
1.17 Per Control Plan / material
E6.6 Rinses have been cleaned per maintenance schedule. Manual
2.11 supplier
2.12
7.0 Cure (See Convective Cure Process Table I)
 CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07

PROCESS TABLE F - Spray

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.0 Part Appearance产品外观

Incoming parts are inspected for cleanliness, trapped water or

Per Control Plan/Log Sheet
1.4 water spots as well as uniform phosphate coating (when
F1.1 Manual手动 (1 per hour)每个控制计划/记录表单（每
2.11 phosphate is used).进料零部件的干净度，限制使用含水或水斑点的产品，使用磷酸盐的产品一
小时１次）
致。（当使用磷酸盐清洁产品时）

F1.2 1.14 Inspection criteria are posted.检验标准被通过。

F1.3 2.10 Adequate lighting is in place.检验地点有充足的照明。

1.4 Mutilation prevention items (i.e. gloves, belt buckle covers, watch
F1.4
2.9 covers, etc.) are in place.在工作中预防(例如手套、预防、手表皮带扣、等等)。

1.4
1.17
F1.5 Paint racks are maintained.油漆架的维护。 Manual手动
2.11
2.12
 CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07

PROCESS TABLE F - Spray

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
2.0 Paint Mixing拌料

1.4 Paint mixing rooms are controlled (mixing tank grounding, closed
Automatic/Manual Per Paint Manufacturer
F2.1 2.11 container, properly enclosed space, temperature, clean
自动/手动 Recommendation建议每个喷涂车间
2.12 environment).拌料间是受控的（混合槽,密封的容器,正确封闭的空间、温度、干净的环境）

1.4
Per Paint Manufacturer
F2.2 2.11 FIFO system is being utilized.使用先进先出系统 Manual手动
Recommendation建议每个喷涂车间
2.12
1.4
1.6
Paint agitation/time and reduction (solvent package) are proper Per Paint Manufacturer
F2.3 1.17 Manual手动
and documented.油漆搅拌/时间,正确稀释(一桶溶剂)和有记录。 Recommendation建议每个喷涂车间
2.11
2.12
1.4
1.6 Per Control Plan/Log
Viscosity and temperature are in operational limits and
F2.4 1.17 Manual Sheet/Paint Manufacturer
documented.粘度和温度在限度范围内并且有记录。
2.11 Recommendation
2.12

1.4
1.6 Per Control Plan/Log
The proper filter size and type are in place.适当的过滤器的尺寸和类型在喷涂线
F2.5 1.17 Manual Sheet/Paint Manufacturer
。
2.11 Recommendation
2.12

1.4
Per Control Plan/Log
1.6
Sheet/Paint Manufacturer
F2.6 1.17 Pump pressures are set within operational limits.泵在压力范围内设置操作。 Manual
Recommendation每个控制计划/表单
2.11
记录/建议每个喷涂车间
2.12
1.4
Circulation (flow meter, pressure gage) is monitored.循环(流量计、压力 Per Control Plan/Log Sheet每
F2.7 2.11 Automatic/Manual
计)监控。 个控制计划/表单记录
2.12
1.4 Bag filter pressures are monitored (bags are changed when psi
Automatic/Manual Per Control Plan/Log Sheet每
F2.8 2.11 differential >5-10 PSI).袋式除尘器的压力监测(当空气压力有变化时（5~10镑/平米）袋
自动/手动 个控制计划/表单记录
2.12 子要更换)。
 CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07

PROCESS TABLE F - Spray

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
Substrate Conditioning (Flame, Plasma, etc) (If
3.0
applicable)素材条件（火焰，等离子等）（假如合适）

1.4 Incoming parts are inspected to ensure that they are free of dirt
F3.1 Manual手动
2.11 and contamination.进料零部件的检验,以确保它们是没有灰尘和污物。

1.4
Flame/Plasma is set at operational limits per equipment and Per control plan and
1.17 2.11
F3.2 material supplier recommendations.火焰、等离子体在操作范围,设备和材料供应商的 Automatic equipment and substrate
建议。 suppliers recommendations
2.12
1.4
F3.3 2.11 Final surface tension is within specifications.最后的表面张力是符合规格。 Manual Per Control Plan
2.13
4.0 Primer/Promoter打底剂/促进剂

1.4 Incoming parts are inspected to ensure that they are free of dirt Per Control Plan/Log Sheet
F4.1 Manual
2.11 and contamination. 进料零部件的检验,以确保它们是没有灰尘和污物。 (1/shift minimum)

1.4
1.17 Destaticizing air is operational. (Plastic parts only)可用的静电除尘（只适用 Per Control Plan/Log Sheet
F4.2 Automatic
2.11 于注塑件） 1 / week
2.12
1.4
Per Control Plan/Log Sheet
F4.3 2.11 Booth balance is monitored. Manual
1 / week
2.12
1.4
1.6 Booth temperature and humidity are monitored (or set within
Per Control Plan/Log Sheet
F4.4 1.17 operational limits if controlled).底漆间的温度和湿度是受监控的（或者在范围内操作如果 Automatic/Manual
(1/shift minimum)
2.11 控制范围）
2.12
1.4
Per control plan and
F4.5 2.11 Film thickness is per customer requirements.膜厚度是符合客户要求的 Manual
customer requirements
2.12
1.4
1.6 Atomizer parameters (fluid flow, air pressures (atomizing fan,
Per Control Plan/Log Sheet
F4.6 1.17 shaping), electrostatics and mixing) are set within operational Automatic/Manual
(1 per month minimum)
2.11 limits.雾化参数（流体流动，空气压力（离心式风机，形状）静电和搅拌）设置在操作范围内
2.12
 CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07

PROCESS TABLE F - Spray

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
5.0 Basecoat (If applicable)底漆（假如合适）
Per Control Plan / material
1.4 Incoming parts are inspected to ensure that they are free of dirt
F5.1 Manual supplier (once per shift
2.11 and contamination. 进料零部件的检验,以确保它们是没有灰尘和污物。
minimum)
1.4
1.6 Flashtimes between coats are set at suppliers recommended Per Control Plan/material
F5.2 Automatic/Manual
2.11 times. supplier
2.13
1.4
1.6 Booth temperature and humidity are monitored or set within
Per Control Plan/Log Sheet
F5.3 1.17 operational limits if controlled. (Required for waterborne Automatic/Manual
(1/shift minimum)
2.11 coatings)底漆车间的温度和湿度是受监控的或者设置在操作范围内（水性漆是必须）
2.12
1.4
1.6 Atomizer parameters (fluid flow, air pressures (atomizing fan,
Per Control Plan/Log Sheet
F5.4 1.17 shaping), electrostatics and mixing) are set within operational Automatic/Manual
(1 per month minimum)
2.11 limits.雾化参数（流体流动，空气压力（离心式风机，形状）静电和搅拌）设置在操作范围内
2.12
1.4
Per Control Plan and
F5.5 2.11 Film builds are per supplier recommendations.成膜按照每个供应商建议 Manual
suppliers recommendations
2.13
Basecoat Heated Flash (Waterborne Materials Only)（只适用于水性
6.0
漆）
1.4
Set point is at suppliers recommended time, temperature and
1.6 Per Control Plan / material
F6.1 energy type (convection/IR/UV/etc.).根据供应商提供的时间、温度和固化类型（对流 Manual
2.11 supplier
／红外线／紫外线）设置合适的控制点。
2.13
1.4
1.6 Percent solids after pre-dry is at the suppliers recommended Per Control Plan/Log Sheet
F6.2 Manual手动
2.11 percentage.预干燥后的固化是遵循供应商推荐的百分比 (1/shift minimum)
2.13
1.4
1.17 Per Control Plan / material
F6.3 The pre-dry oven is maintained. 预干燥箱的维护 Manual
2.11 supplier
2.12
 CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07

PROCESS TABLE F - Spray

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
7.0 Clearcoat（面漆）
Per Control Plan / material
1.4 Incoming parts are inspected to ensure that they are free of dirt
F7.1 Manual supplier (once per shift
2.11 and contamination.进料零部件的检验,以确保它们是没有灰尘和污物。
minimum)
1.4
1.6 Flashtimes between coats are set at suppliers recommended Per Control Plan/material
F7.2 Automatic/Manual
2.11 times. supplier
2.13
1.4
1.6 Booth temperature and humidity are monitored or set within
Per Control Plan/Log Sheet
F7.3 1.17 operational limits if controlled. (Required for waterborne Automatic/Manual
(1/shift minimum)
2.11 coatings)面漆房间的温度和湿度是受监控的或者设置在操作范围内（水性漆是必须）
2.12
1.4
1.6 Atomizer parameters (fluid flow, air pressures (atomizing fan,
Per Control Plan/Log Sheet
F7.4 1.17 shaping), electrostatics and mixing) are set within operational Automatic/Manual
(1 per month minimum)
2.11 limits.雾化参数（流体流动，空气压力（离心式风机，形状）静电和搅拌）设置在操作范围内
2.12
8.0 Cure (See Convective Cure Process Table I)

9.0 Final Part Inspection成品检验

F9.1 1.14 Inspection criteria are posted.有检验规范

F9.2 2.10 There is adequate lighting in inspection area.检验的地方有充足的光照。

1.4
F9.3 Mutilation prevention items are in place.
2.9
1.4
1.8
F9.4 Defects are being tracked.跟踪不良品 Manual Per Control Plan
1.12
2.13
1.4
F9.5 FTT is being monitored.一次下线合格率是受监控的。 Manual Per Control Plan
2.13
1.10
F9.6 1.11 Scrap and repaints are being tracked.跟踪报废和返喷产品。 Manual手动 Per Control Plan
1.12
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE G - Dip/Spin

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job
audit, the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.0 Coating Material Application

1.4 After pretreatment, parts are inspected for flash rust, Per Control Plan/Log Sheet
G1.1 Manual
2.11 wetness, oil or other defects. (each lot)

1.4 If phosphated, parts are checked for uniformity of Per Control Plan/Log Sheet
G1.2 Automatic/Manual
2.11 phosphate coating. (1/shift minimum)

Skids/bins used to hold parts between coating

2.6 Per Control Plan/Log Sheet
G1.3 operations are free of oil, grease or other Manual
1.17 (each lot)
contaminants.
2.0 Coating Bath
1.4
G2.1 2.11 Incoming paint viscosity is checked. Manual Each New Lot of Paint
2.12
1.4
G2.2 2.11 Incoming solids checks are performed. Manual Each New Lot of Paint
2.12
1.4
1.17 Appropriate mixing equipment is used, capable of
G2.3 Manual Ongoing
2.11 dispersing settled solids.
2.12

2.9 Paint is stored properly, away from high humidity and

G2.4 Manual Ongoing
2.10 temperature extremes.

2.9
G2.5 Paint is kept covered and/or sealed when not in use. Manual Ongoing
2.10

2.9 Paint storage room is organized so each paint is

G2.6 Manual Ongoing
2.10 easily found to prevent contamination.
2.9
G2.7 Paint storage room is kept clean. Manual Ongoing
2.10
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE G - Dip/Spin

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job
audit, the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
The following checks shall be performed during
G2.8
production:
1.4
Per Control Plan/Log Sheet
G2.9 2.11 Paint Temperature. Manual
(3/shift minimum)
2.12

1.4
Per Control Plan/Log Sheet
G2.10 2.11 Viscosity. Manual
(3/shift minimum)
2.12

1.4
Per Control Plan/Log Sheet
G2.11 2.11 % Solids (by weight). Manual
(1/Day minimum)
2.12

1.4
Per Control Plan/Log Sheet
G2.12 2.11 Volume (paint depth in coating vat). Automatic/Manual
(3/shift minimum)
2.12

1.4
Per Control Plan/Log Sheet
G2.13 2.11 Vibratory feed tables are cleaned (if used). Manual
(as needed)
2.12
1.4
1.17 Basket condition (basket mesh clean and Per Control Plan/Log Sheet
G2.14 Manual
2.11 undamaged). (as needed)
2.12
1.4
Per Control Plan/Log Sheet
G2.15 2.11 Paint and/or solvent additions are documented. Manual
(each addition)
2.12

Per Control Plan/Log Sheet

G2.16 2.10 Viscosity cups are cleaned after each use. Manual
(each check)

2.14
G2.17 Viscosity cups are verified. Manual 2/Month minimum
1.17
2.14
G2.18 Thermometers are calibrated/verified. Manual Once/Month minimum
1.17
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE G - Dip/Spin

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job
audit, the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
3.0 Application Parameters
A system is in place to ensure proper basket weights
1.4 Per Control Plan/Log Sheet
G3.1 for specific parts, such as processing manual, Automatic/Manual
1.6 (each lot)
traveller, or process recipe.

1.4 Per Control Plan/Log Sheet

G3.2 Baskets are kept less than 2/3 full. Automatic/Manual
1.6 (each lot)

1.4 Per Control Plan/Log Sheet

G3.3 Dip time is controlled. Automatic/Manual
1.6 (each lot)

1.4 Per Control Plan/Log Sheet

G3.4 Spin speed (RPM) is controlled. Automatic/Manual
1.6 (each lot)

1.4
G3.5 1.6 The coating unit has an attached RPM indicator.
1.17
1.4
G3.6 1.6 RPM's can be adjusted easily.
1.17

1.4 Per Control Plan/Log Sheet

G3.7 Spin time is controlled. Automatic/Manual
1.6 (each lot)

1.4 The number of spins is adjustable (single, double,

G3.8 Automatic/Manual
1.6 triple).
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE G - Dip/Spin

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job
audit, the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #

1.4 Tumble time is in/out of coating controlled (if Per Control Plan/Log Sheet
G3.9 Automatic/Manual
1.6 applicable). (each lot)

1.4
There is an adequate system to keep parts level Per Control Plan/Log Sheet
G3.10 1.6 Automatic/Manual
going into the oven (raking, vibe table, etc.). (each lot)
1.17

Per Control Plan/Log Sheet

G3.11 2.10 Vibratory feed tables are cleaned (if used). Manual
(as needed)

There is evidence of steps taken to assist in soft

Per Control Plan/Log Sheet
G3.12 2.9 handling of parts (shallow drops, lined chutes and Automatic/Manual
(each lot)
hoppers, bumper boards, etc.).
1.4
G3.13 2.9 Parts are cool to to touch before each coating step. Manual Per Control Plan (each lot)
2.11
4.0 Cure (See Convective Cure Process Table I)
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE H - Autophoretic

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit,
the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.0 3.1 Coating Bath
1.4
Mixer speed and direction are monitored and Per Control Plan/Log Sheet
H1.1 2.11 Automatic/Manual
adjusted. (1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log Sheet
H1.2 Time (hoist program) is verified. Automatic/Manual
2.11 (1/day minimum)
2.12
1.4
1.17 Annually or after repair
H1.3 Conveyor speed is verified (if applicable). Manual
2.11
2.12
1.4
1.6 Per Control Plan/Log Sheet
H1.4 Temperature is monitored and controlled. Automatic
2.11 (1/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
H1.5 2.11 Humidity level is monitored. Automatic/Manual
(1/shift minimum)
2.12

1.4
Per Control Plan/Log Sheet
H1.6 2.11 101 (fluoride) and ORP levels are checked. Automatic/Manual
(every 2 hours minimum)
2.12

1.4
Chemical concentration (% solids, starter/iron Per Control Plan/Log Sheet
H1.7 2.11 Automatic/Manual
titration, conductivity) is checked and maintained. (1/shift minimum)
2.12
1.4
Per PM schedule
1.17
H1.8 Bath transfer is maintained. Manual (1/year
2.11
minimum)
2.12
2.0 1.18 Tap Rinse After Coating
1.4
Per Control Plan/Log Sheet
H2.1 2.11 Pump pressure or agitator speed is monitored. Automatic/Manual
(1/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
H2.2 2.11 Impurity concentration (conductivity) is checked. Automatic/Manual
(1/shift minimum)
2.12
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE H - Autophoretic

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit,
the auditor shall verify coater is conforming to customer requirements.

Related
Item # Category/Process Steps Control Monitoring
CSA Question #
3.0 3.2 Reaction Rinse
1.4
Chemical concentration (titration, conductivity, Per Control Plan/Log Sheet
H3.1 2.11 Automatic/Manual
pH, Hach Meter Test) is checked and maintained. (1/shift minimum)
2.12

1.4
Per Control Plan/Log Sheet
H3.2 2.11 Pump pressure or agitator speed is monitored. Automatic/Manual
(1/shift minimum)
2.12

1.4
Temperature is monitored and controlled (if Per Control Plan/Log Sheet
H3.3 2.11 Automatic/Manual
applicable). (1/shift minimum)
2.12
1.4
1.17 Per Chemical Manufacturer's
H3.4 There is a dump schedule. Manual
2.11 Guideline (minimum 3 times per year)
2.12

4.0 Cure (See Convective Cure Process Table I)

 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE I - Convective Cure

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall
verify coater is conforming to customer requirements.

Item # Related
Category/Process Steps Control Monitoring
CSA Question #
1.0
1.4
1/shift minimum or at every material
1.6 Oven temperature set point and limits are checked and
I1.1 Automatic自动 change. Per coating supplier
2.11 documented.检查并记录烘箱的温度设置点和限度
recommendation
2.12

I1.2 1.17 Part temperature profile is monitored.监控烘箱的温度曲线 Manual手动 1/month minimum

1.4
1.6 Proper cure time is maintained (if applicable).保持合适的固化时间（假如可能 Per coating supplier recommendation 每
I1.3 Automatic/Manual
2.11 ） 个油漆供应商的建议
2.12

1.4
1.6
Conveyor speed is maintained (if applicable).保持合适的传送速度（假如可能
I1.4 1.17 Automatic 1/month minimum (after PM)
）
2.11
2.12
1.4
Airflow is measured (if required by coating supplier).测量空气流动（假如 Per coating supplier recommendation每
I1.5 2.11 Automatic/Manual
需要油漆供应商） 个油漆供应商建议
2.12

Per oven manufacturer, filter supplier

I1.6 1.17 Air filter change is scheduled.有计划的更换空气过滤装置 Manual
recommendation每个烘箱，过滤装置供应商的建议

I1.7 1.17 Thermocouple for oven control is calibrated.烘箱中的热电偶可测量

Per coating supplier recommendation 每

I1.8 2.13 Cure testing is conducted by laboratory.固化测试由实验室实施。 Manual
个油漆供应商建议

Per Control Plan/Log Sheet

I1.9 2.13 Final color is monitored.最终颜色测量 Manual
(1/shift or color change minimum)

Per Control Plan/Log Sheet

I1.10 2.13 Film thickness/coating weight is monitored.检测膜厚/油漆重量 Manual
(1/shift or color change minimum)

I1.11 2.13 Gaugeability is checked (if applicable). Manual Per customer requirements

Per Control Plan/Log Sheet

I1.12 2.13 Paint adhesion is monitored.油漆粘度的测量 Manual (1/shift or color change minimum)每个控制
计划/表单记录（至少1次/班或颜色变更）
 CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07

PROCESS TABLE J - EQUIPMENT

All requirements given below are subordinate to customer specific requirements. 下面是所有要求给予下属顾客的特殊要求。

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.客户可
以附加条件,例如,检验测试、增大频率等。当执行审核、审核员应当审核喷涂线以满足客户的需求。

PROCESS EQUIPMENT
Related
Item #项 Pretreatment Powder E-Coat电 Spray喷 Dip/Spin Calibration
CSA Question # A-Coat Cure Verification Frequency Comment
目 预处理 Coat粉末喷涂 镀喷涂 涂 浸镀/旋转喷涂 Frequency
相关的CSA条款
1.1 2.14 X X X X X pH Meter/Probe PH测量 Daily Yearly
1.2 2.14 X X X X X X X Temperature Controller 温度控制 At Start-up 2x/Year
1.3 2.14 X X Rectifier At Start-up N/A
Phosphate - 3hr min.
1.4 2.14 X X X X X Wet Analysis湿度分析 Paint Lines - Before Run N/A
E-Coat - 1x/Shift min.
1.5 2.14 X Atomic Absorption (Optional)
1.6 2.14 X X X X X X XFilters过滤装置 * N/A * As needed based on pressure.
1.7 2.14 X X X Balance 1x/Week Yearly
1.8 2.14 X X Coductivity Meter Before Use Yearly
1.9 2.14 X X Viscosity Measurement粘度测量 Hourly每小时 Monthly 没有校准
1.10 2.14 X Thermocouple N/A 2x/Year
MINIMUM REQUIRED TESTING CAPABILITY
2.1 2.14 X X X X X X Salt Spray Cabinet盐雾箱 没有
2.2 2.14 X X X X X Water Immersion Tank水槽 没有
2.3 2.14 X Environmental Chamber
2.4 2.14 X Cure Testing (chemical rubbing)
2.5 2.14 X X X X X X Adhesion Testing 粘度测试 有
2.6 2.14 X X X X X X Thickness Testing膜厚测试 有
2.7 2.14 X X X X X X Microscope (when applicable)显微 没有
镜（合适的时候）
2.8 2.14 X Freezer (plastic substrate)冷藏室（塑
料底板）
2.9 2.14 X Lab Oven 烘箱