Cqi 9

CQI-9
Special Process: Heat Treat System Assessment

Version 2, Issue 8/07
Facility Name:
Number 616-243-0178
Fax Number: 616-243-6337 Process Table A - Ferrous
Carburizing
Carbonitriding
15 Carbon Correction
Captive Heat
Treater (Y/N):
N Neutral Hardening
Quench & Temper
Commercial
Heat Treater
Y Austempering / Martempering
Tempering
Date of
Assessment:
28-Feb-2011 Precipitation Hardening / Aging
Date of Previous
Assessment:
20-Feb-2010
Process Table B - Ferrous
Nitriding (Gas)
Ferritic-Nitrocarburizing (Gas or Salt)
Process Table C - Aluminum
Aluminum Heat Treatment
Process Table D - Ferrous
Induction Heat Treating
Process Table E
Annealing
Normalizing
Stress-Relieving
Name: Title: Phone:
J ESSE
MEESENGILL OWNER/PRESIDENT 616-243-0178
PAUL MEENGS V.P. OF OPERATIONS 616-243-0178
CHARLES
TUTTLE
PRODUCTION
SUPERVISOR 616-243-0178
Name: Company: Phone:
PAUL MEENGS
STATE HEAT
TREATING 616-243-0178
CHARLES
TUTTLE
STATE HEAT
TREATING 616-243-0178
Number of " Not Satisfactory" Findings:
0
Number of " Needs Immediate Action" Findings:
0
Number of " Fail" Findings in the Job Audit(s):
Email:
paulm@stateheattreating.com
charlie@stateheattreating.com
X
paulm@stateheattreating.com
jmassengill@corlett.com
Personnel Contacted:
0
X
X
X
X
X
X
02/19/2013
ISO 9001:2008 REGISTRATION ENDING 02/19/2013
X
X
X
Date of Re-assessment (if necessary):
Auditors/Assessors:
charlie@stateheattreating.com
Email:
Current Quality
Certification(s):
STATE HEAT TREATING
Address: 520 32ND ST. SE. GRAND RAPIDS, MICHIGAN 49548
Type(s) of Thermal Processing at this Facility:
Number of Heat Treat Employees at this
X
X
CQI-9
Number Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Needs
Immediate
Action
1.1
Is there a dedicated and
qualified heat treat
person on-site?
To ensure readily available expertise, there shall be a
dedicated and qualified heat treat person on site. This
individual shall be a full-time employee and the
position shall be reflected in the organization chart. A
job description shall exist identifying the qualifications
for the position including metallurgical and heat treat
knowledge. The qualifications shall include a minimum
of 5 years experience in heat treat operations or a
combination of a minimum of 5 years of formal
metallurgical education and heat treat experience.
Paul Meengs has worked in the heat treat
industry for 35+years. Charles Tuttle, the
plant supervisor has 12 years of heat treat
experience.
X
1.2
Does the heat treater
perform advanced
quality planning?
The organization shall incorporate a documented
advance quality planning procedure. A feasibility
study shall be performed and internally approved for
each part. Similar parts can be grouped into part
families for this effort as defined by the organization.
After the part approval process is approved by the
customer, no process changes are allowed unless
approved by the customer. The heat treater shall
contact the customer when clarification of process
changes is required. This clarification of process
changes shall be documented.
Every new part is reviewed and processed
per a generic FEMA and CONTROL plan.
Every part receives its own process with all
changes and modifications recorded. See
work instructions 7-10-102 Quality Planning,
7-20-603 Changes to requirements.
X
Assessment
Section 1 - Management Responsibility & Quality Planning
CQI-9
Needs
Immediate
Action
Assessment
1.3
Are heat treat FMEA's
up to date and reflecting
current processing?
The organization shall incorporate the use of a
documented Failure Mode and Effects Analysis
(FMEA) procedure and ensure the FMEA's 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 shall address all process
steps from part receipt to part shipment and all key
heat treat process parameters as defined by the
organization. A cross-functional team shall be used in
the development of the FMEA. All special
characteristics, as defined by the organization and its
customers, shall be identified, defined, and addressed
in the FMEA.
FMEA's are done for families of parts and
process's. Each plan is reviewed yearly with
all changes recorded on the FMEA. See
attached sample FMEA.
X
CQI-9
Needs
Immediate
Action
Assessment
1.4
Are heat treat process
control plans up to date
and reflecting current
processing?
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 heat treat
process parameters as defined by the organization.
A cross-functional team, including a production
operator, shall be used in the development of Control
Plans, which shall be consistent with all associated
documentation such as work instructions, shop
travelers, and FMEA's. All special characteristics, as
defined by the organization and its customers, shall
be identified, 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, Sections 3.0 and 4.0.
Control plans are done for part/process
families. Each plan is reviewed yearly with all
changes recorded on the control plan. See
attached copy of Control plan.
X
CQI-9
Needs
Immediate
Action
Assessment
1.5
Are all heat treat related
and referenced
specifications current
and available? For
example: SAE, AIAG,
ASTM, General Motors,
Ford, and
DaimlerChrysler.
To ensure all customer requirements are both
understood and satisfied, the organization shall have
all related heat treat 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 customer and industry
engineering standards / specifications and changes
based on customer-required schedule. Timely review
should be as soon as possible and shall not exceed
two working weeks. The organization shall document
this process of review and implementation, and it shall
address how customer and industry documents are
obtained, how they are maintained within the
organization, how the current status is established,
and how the relevant information is cascaded to the
shop floor within the two-week period. The
organization shall identify who is responsible for
performing these
tasks.
All specifications used for any given process
will be indicated on the control plan and will
be updated along with the review of the plan
at its yearly review. All customer
specifications will be reviewed at receipt and
will not be controlled. Print revisions, if
provided, will be recorded on our internal
process and verified at order entry. See 4-23-
104 PSD Management.
X
CQI-9
Needs
Immediate
Action
Assessment
1.6
Is there a written
process specification for
all active processes?
The heat treater 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,
atmosphere or gas flow settings, belt speeds, quench
agitation speeds, etc. Such parameters shall not only
be defined, they shall have operating tolerances as
defined by the organization in order to maintain
process control.
All active processes should have a written process
specification.
These process specifications may take the form of
work instructions, job card, computer-based recipes,
or other similar documents.
Each part is entered into a computer data
base and has its own individual process.
Along with the process is all routing and
process parameters and any special
instructions. Process Variables specific to
each piece of equipment is posted at the
control panel for operator review. See 7-10-
102 Quality planning.
X
CQI-9
Needs
Immediate
Action
Assessment
1.7
Has a valid product
capability study been
performed initially and
after process equipment
has been relocated, or
had a major rebuild?
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, & 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 heat treat processes per furnace line
defined in scope of work & in accordance with
customer requirements. A furnace line may include a
combination of equipment that is integrated in the
performance of a heat treatment process, e.g.,
hardening, quenching, and tempering. Capability
study techniques shall be appropriate for the heat
treat product characteristics, e.g., tensile strength,
case depth, hardness. Any specific customer
requirements shall be met, in the absence of
customer requirements, the organization shall
establish acceptable ranges for measures of
capability. An action plan shall exist to address the
steps to followed in case capability indices fall outside
customer requirements or
established ranges.
We do capability studies on each furnace line
for each process family that is associated
with that line. The data is recorded on a
Process Capibility Histogram.
` X
CQI-9
Needs
Immediate
Action
Assessment
1.8
collect and analyze data
over time, and react to
this data?
The analysis of products and processes over time can
yield vital information for defect prevention efforts.
The organization shall have a system to collect,
analyze, and react to product or process data over
time.
Methods of analysis shall include ongoing trend or
historical data analysis of product or process
parameters. The organization shall determine which
parameters to include in such analysis.
Ongoing data collection is done on significant
parameters for each process family. Each job
that does not meet the requirements is
recorded on a Problem Analysis and
reviewed at ISO management meetings. See
8-50-301 Problem Analysis, 8-30-304 Work
in process rejection.
X
1.9
Is management
reviewing the heat treat
monitoring system every
24 hours?
Management shall review the furnace monitoring
systems at intervals not to exceed 24 hours. The
heat treat monitoring system includes but is not
limited to temperature strip charts, atmosphere strip
charts, computer data logs, furnace and operator
logs, etc.
The management review shall include efforts to detect
out-of-control conditions or alarm conditions. The
process of reviewing the furnace data shall be
documented and this requirement also applies to
computerized data.
All equipment with electronic data collection
is reviewed daily via computer.
X
1.10
Are internal
assessments being
completed on an annual
basis, at a minimum,
using AIAG HTSA?
The organization shall conduct internal assessments
on an annual basis, at a minimum, using the AIAG
HTSA.
All process elements of the ISO program are
audited once per year by our internal auditor.
Any item not dealt with in the ISO program
will be reviewed on a yearly basis and
updated as needed.
X
CQI-9
Needs
Immediate
Action
Assessment
1.11
Is there a system in
place to authorize
reprocessing and is it
documented?
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.
Any reprocessing activity shall require a new
processing control sheet issued by qualified technical
personnel denoting the necessary heat treat
modifications. Records shall clearly indicate when and
how any material has been reprocessed. The Quality
Manager or a designee shall authorize the release of
reprocessed product.
Any part processed that does not meet the
customers spec is placed on hold and
reviewed by 1 of 2 persons authorized to
place a rework instruction for reprocessing.
All reworked parts are final inspected by
shipping and receiving personnel and all
rework instructions and results are
documented on a new work order and
recorded. See 8-30-303 Control of reworked
product, 8-30-302 Disposition of
nonconforming.
X
1.12
Does the Quality
Department review,
address, and document
customer and internal
concerns?
The quality management system shall include a
process for documenting, reviewing, and addressing
customer concerns and any other concerns internal to
the organization. A disciplined problem-solving
approach shall be used.
Our top 40 customers are surveyed yearly
and all results from the surveys tallied and
added to the Management Review Meetings.
All internal problems are put on a Problem
Analysis and dealt with through our internal
review process. See 8-21-601 Customer
satisfaction.
X
CQI-9
Needs
Immediate
Action
Assessment
1.13
Is there a continual
improvement plan
applicable to each
process defined in the
scope of the
assessment?
The heat treater shall define a process for continual
improvement for each heat treat process identified in
the scope of the HTSA. The process shall be
designed to bring about continual improvement in
quality and productivity. Identified actions shall be
prioritized and shall include timing (estimated
completion dates). The organization shall show
evidence of program effectiveness.
The review of the Control Plan and FEMA will
show what is being done to improve quality
and will be shown by the rpn numbers going
lower with given improvements. Any major
Continual Improvement project will be
controlled by Work Instruction 8-50-306
Continuous Improvement
X
1.14
Does the Quality
Manager or designee
authorize the disposition
of material from
quarantine status?
The Quality Manager is responsible for authorizing
and documenting appropriate personnel to disposition
quarantine material.
1 0f 2 persons are authorized to release "ON
HOLD" product and will document this on the
work order or a Material Deviation report.
See 8-30-303 Control of reworked product.
X
1.15
Are there procedures or
work instructions
available to the heat
treat personnel that
define the heat treating
process?
There shall be procedures or work instructions
available to heat treat personnel covering the heat
treating process. These procedures or work
instructions shall include methods of addressing
potential emergencies (such as power failure),
equipment start-up, equipment shut-down, product
segregation (See 2.8), product inspection, and
general operating procedures. These procedures or
work instructions shall be accessible to shop floor
personnel.
All elements of our process flow have written
procedures and are part of all employees
training. We have these instructions available
for review to all operators.
X
CQI-9
Needs
Immediate
Action
Assessment
1.16
Is management
providing employee
training for heat
treating?
The organization shall provide employee training for
all heat treating operations. All employees, including
backup and temporary employees, shall be trained.
Documented evidence shall be maintained showing
the employees trained and the evidence shall include
an assessment of the effectiveness of the training.
Management shall define the qualification
requirements for each function, and ongoing or follow-
up training shall also be addressed.
Training starts from day 1 and is ongoing and
fully documented. Each employee has an
ongoing Employee Qualification on file with
new levels added as required. See 6-20-402
Qualifying Employees.
X
1.17
Is there a responsibility
matrix to ensure that all
key management and
supervisory functions
are performed by
qualified personnel?
The organization shall maintain a responsibility matrix
identifying all key management and supervisory
functions and the qualified personnel who may
perform such functions. It shall identify both primary
and secondary (backup) personnel for the key
functions (as defined by the organization). This matrix
shall be readily available to management at all times.
An organizational chart is posted at the time
clock listing the reporting structure of the
company. In addition each persons job
description lists their responsibility's, who
they report to and their authority when
dealing with rejects. See 5-00-401
Organization charts and 5-00-402 J ob
descriptions.
X
CQI-9
Needs
Immediate
Action
Assessment
1.18
Is there a preventive
maintenance program?
Is maintenance data
being utilized to form a
predictive maintenance
program?
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 assessment of
effectiveness. Equipment operators shall have the
opportunity to report problems, and problems shall
also be handled in a closed-loop manner.
Company data, e.g., downtime, quality rejects, first-
time-through capability, recurring maintenance work
orders, and operator-reported problems, shall be used
to improve the preventive maintenance program.
Furnaces and generators shall be scheduled for burn-
out at frequencies determined by the organization
(see Section 1 of the Process Tables).
Maintenance data shall be collected and analyzed as
part of a predictive maintenance program.
A full and complete preventive maintenance
program (Maintimizer) is written and used.
The PM assignments are reviewed monthly
with changes and modifications documented.
All maintenance purchasing and inventory is
maintained within this program. All critical
parts are listed and purchased from
approved suppliers only. See 7-40-502
Approved suppliers and 7-40-503 Purchase
order & review.
X
1.19
Has the Heat Treater
developed a critical
spare part list and are
the parts available to
minimize production
disruptions?
The heat treater shall develop and maintain a critical
spare parts list and shall ensure the availability of
such parts to minimize production disruptions.
See 1.18 X
CQI-9
Needs
Immediate
Action
Assessment
2.1
Does the facility ensure
that the data entered in
the receiving system
matches the information
on the customer's
shipping documents?
It is critical that all customer requirements and lot
identification be adequately transferred to internal
heat treat documents. The facility shall ensure that
the data entered in the receiving system match the
information on the customer's shipping documents.
Documented processes and evidence of compliance
shall exist, e.g., shop travelers, work orders, etc.
Sometimes the material received does not precisely
correspond to customer shipping documents. The
facility shall have a detailed process in place to
resolve receiving discrepancies.
The requirements stated above also apply to captive
heat treat departments. This process refers to
receiving and shipping the parts in and out of the heat
treat department.
All incoming product is reviewed for accuracy
at receiving. All information provided is
verified with our process and recorded on the
customers document. Any discrepancies are
documented and product is placed on hold
pending a review by engineering. See 7-20-
601 Products requirements review.
X
2.2
Is product clearly
identified and staged
throughout the heat treat
process?
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 product
shall be clearly identified and staged throughout the
heat treat process. Non-heat treated, in-process, and
finished product shall be properly segregated and
identified. All material shall be staged in a dedicated
and clearly defined area.
All product is staged in set areas waiting for
processing. During process it is identified by
load tags and with the work order. All finished
product is in a "done ready to ship" area with
all parts identified with the work order. See 7-
50-202 Work order/data sheet.
X
CQI-9
Needs
Immediate
Action
Assessment
2.3
Is lot traceability and
integrity maintained
throughout all
processes?
Out-going lot(s) shall be traceable to the incoming
lot(s).
The discipline of precisely identifying lots and linking
all pertinent information to them enhances the ability
to do root cause analysis and continual improvement.
All lots have their own work order. All work
orders are kept separate during processing
and will remain so during shipment back to
the customer. See 7-50-205 Identification
and traceability
X
2.4
Are procedures
adequate to prevent
movement of non-
conforming product into
the production system?
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-conforming
product into the production system. Procedures shall
exist addressing proper disposition, product
identification, and tracking of material flow in and out
of the hold area. A non-conforming hold area shall be
clearly designated to maintain segregation of such
material.
All product that does not meet the customers
specifications will be red tagged / and or
rejected on the work order and placed in the
"hold area" See 8-30-301 Identity / control
nonconforming.
X
CQI-9
Needs
Immediate
Action
Assessment
2.5
Is there a system to
identify trap points in the
entire heat treat process
to reduce risk of mixed
parts (inappropriate, non-
heat treated, or
improperly heat treated
parts)?
Heat-treating furnaces and other processing
equipment contain areas that have a risk of trapping
or holding parts. Such trapping of parts can lead to
damage, improperly processed parts or lot
mixing/contamination. A system shall exist to identify
trap points in the entire heat treat process to reduce
risk of mixed parts (inappropriate, non-heat treated, or
improperly heat treated parts). The heat treater shall
have documented procedures to identify and monitor
trap points for each process/equipment. Monitoring of
potential trap points shall occur for every part
changeover.
The preventative maintenance program
generates a work order for a review of each
lines operation and identify additional areas
for improvement.
X
2.6
Are containers free of
inappropriate material?
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 material have
been removed. The source of inappropriate material
shall be identified and addressed. This is to ensure
that no nonconforming heat treated parts or
inappropriate material contaminate the finished lot.
Each container is removed from the loading
area and looked at prior to returning to the
finished parts area. Any foreign material is
removed.
X
CQI-9
Needs
Immediate
Action
Assessment
2.7
Is furnace loading
specified, documented
and controlled?
Furnace loading parameters shall be specified,
documented, and controlled. Examples include feed
rate, belt speed, number of parts per fixture, and load
weight. Refer to Process Tables, Section 3.0, for
frequency of checks.
All process's have loading requirements
documented on the work order. The operator
logs the loading on the furnace log each
order and at shift change. This is verified by
shift supervisor and reviewed by
management daily. See 7-50-203 Process
validation.
X
2.8
Are operators trained in
material handling,
containment action and
product segregation in
the event of an
equipment emergency
including power failure?
Unplanned or emergency downtime greatly raises the
risk of improper processing. Operators shall be
trained in material handling, containment action, and
product segregation in the event of an equipment
emergency including power failure. Training shall be
documented. Work instructions specifically
addressing potential types of equipment emergencies
and failures shall be accessible to and understood by
equipment operators. These instructions shall
address containment actions related to all elements of
the heat-treating process, e.g., loading, austentizing,
quenching, tempering.
Our Work in Process rejection procedure
covers all nonconforming situations and is
part of all employees regular training. See 8-
30-304 Work in process rejection.
X
CQI-9
Needs
Immediate
Action
Assessment
2.9
Is the handling, storage
and packaging adequate
to preserve product
quality?
Handling, storage, and packaging shall be adequate
to preserve product quality. The heat treaters
furnace loading system, in-process handling, and
shipping process shall be assessed for risk of part
damage or other quality concerns.
Some equipment includes conveyors and other
moving components that may not be able to handle all
part configurations. Other practices such as stacking
of overloaded containers can also increase the risk of
part damage.
Each process that is assessed to
potentionally damage a part during transport,
loading, processing, unloading and transport
has special processing for hand load, hand
unload, special racking instructions, and / or
special shipping instructions. See 7-50-207
Preservation of product.
X
2.10
Are plant cleanliness,
housekeeping,
environmental and
working conditions
conducive to control and
improved quality?
Plant cleanliness, housekeeping, environmental, and
working conditions shall be conducive to controlling
and improving quality. The heat treater should
evaluate such conditions and their effect on quality. A
housekeeping policy shall be clearly defined and
executed. The facility shall be reviewed for conditions
that are detrimental to quality processing such as
loose parts on floor, oil around quench tanks,
inadequate plant lighting, smoke, etc.
A plant survey is done by an internal auditor
monthly to evaluate the plant for building
maintenance, lighting, cleanliness, and
organization. This is one of the Management
review measurables. See 6-30-205
Housekeeping.
X
CQI-9
Needs
Immediate
Action
Assessment
2.11
Are parts free from
contaminants that would
be detrimental to the
heat treatment of the
product?
Many heat-treated parts are subjected to surface
finish or appearance operations such as plating or
coating after heat treatment. Parts shall be free from
contaminants that are detrimental to subsequent
processes or the product. Pre-wash (if applicable)
and post-wash parameters shall be monitored and
documented. Oils and other contaminants or residues
can be difficult to remove once subjected to the heat
treatment process. Review the chemical suppliers
recommendation for cleaning the system. Parts shall
be free of rust, burrs, chips, detrimental amounts of
drawing compound, cutting fluids, rust preventing oils,
lubricants, etc., prior to heat treat.
Note: Refer to the appropriate heat treater's
requirements and specifications to determine
acceptability. Refer to Process Table, Section 5.0, for
frequency of checking washer solutions.
Any part with detrimental amounts of oils or
drawing compounds are prewashed and all
product is post washed prior to temper. All
washers are on a preventive maintenance
program and checked and recorded 3 times
per week. Additions are recorded and
evaluated. We do not find any need for daily
checks with the data showing no out of
tolerance readings on a 3 day schedule. All
washer concentrations are verified by the
soap supplier quarterly or as needed.
X
CQI-9
Needs
Immediate
Action
Assessment
2.12
Is the quenching system
monitored, documented,
and controlled?
The quenching system shall be monitored,
documented, and controlled. The temperature,
agitation, level, concentration (if applicable), time in
the quenchant, and additions shall be controlled to the
heat treater's specifications. Refer to Process Tables,
Sections 3.0 and 5.0, for frequency of checks.
Computer-monitoring equipment, with alarms and
alarm logs, satisfy the verification requirement.
Quench delay tolerance and alarm is required for
furnaces with integral quench tanks. Temper delay
time shall be specified by the heat treater for parts
that are quenched and tempered, e.g., carburizing,
carbonitriding, neutral hardening, solution treating and
aging.
The oil levels are checked manually every
other day. All levels are recorded and
documented on the pm request. The
temperature, agitation speed, time in the
quench are all automatically controlled.
Quench delay timers and alarms are
available on each furnace.
X
2.13
Is soluble oil or other
rust preventive
monitored and controlled
if applicable?
Parts are often dipped in or sprayed with rust
preventive solutions immediately after the heat
treating process. Soluble oil solutions or other rust
preventive solutions shall be monitored and
controlled, if applicable. The heat treater shall have
and maintain documented tolerances for the solutions.
Refer to Process Tables, Section 5.0, for frequency of
checks.
The only analysis done on this product is to
check for density. This will be performed by
the supplier quarterly.
x
2.14
Are process control
parameters monitored
per frequencies
specified in Process
Tables?
Process control parameters shall be monitored per
frequencies specified in Process Tables. Refer to
Process Tables, Section 3.0. Computer monitoring
equipment with alarms and alarm logs satisfy the
verification requirement. A designated floor person
shall verify the process parameters, e.g., by initialing
a strip chart or data log. Management review is
required per Question 1.9.
All required process control parameters are
continuously recorded and signed off by the
operator at shift change at least every 8
hours. This is verified every 3 hours by the
shift supervisor.
X
CQI-9
Needs
Immediate
Action
Assessment
2.15
Are In-Process / Final
Test Frequencies
performed as specified
in Process Tables?
In-Process / Final Test Frequencies shall be
performed as specified in Process Tables. Refer to
Process Tables, Section 4.0.
Yes. See shop records. See 8-24-201 Work
in process inspection and 8-24-301 Final
inspection.
X
2.16
Is product test
equipment verified?
Product test equipment shall be verified. Test
equipment shall be verified/calibrated per applicable
customer-specific standard or per an applicable
consensus standard such as those published by
ASTM, DIN, EN, ISO, J IS, NIST, SAE etc.
Verification/calibration results shall be internally
reviewed, approved, and documented. Refer to
Process Tables, Section 1.0, for frequency of checks.
An outside service does the calibrations on
all test equipment semi-annually. All test
equipment is verified internally on a daily
basis. See 7-60-301 Inspection measuring
and testing equipment ID & Schedule and 7-
60-305 Calibration records.
X
3.1
Do furnaces, generators,
and quench systems
have proper process
control equipment?
The heat-treat furnaces, generators, and quench
systems shall have proper process controls and
related equipment. Examples include temperature,
carbon potential/dew point, gas flows, quench
monitoring system including agitation, temperature
control and quenching oil analysis, etc. as listed in the
applicable Process Tables, Section 1.0.
All equipment has automatic temperature
controls, cycle timers, agitation control,
carbon control, oil temperature and flow
scopes for each zone. All controls are
calibrated semi-annually.
X
3.2
Are process equipment
calibrations and/or
verification certified,
posted, and current?
The calibration and certification of the process
equipment shall be checked at regular specified
intervals. Refer to the applicable Process Tables,
Sections 1.0 and 2.0, for equipment calibration or
certification time tables.
All calibrations are posted at/on the control or
equipment being certified. All internal
verifications are also posted at the equipment
X
Section 3 - Equipment
CQI-9
Needs
Immediate
Action
Assessment
3.3
Are thermocouples &
protection tubes
checked or replaced per
Process Tables?
The thermocouples and protection tubes shall be
checked or replaced in compliance to a preventive
maintenance schedule. Refer to the applicable
Process Tables, Section 2.0.
All thermocouples are changed out per our
pm program semiannually. All protection
tubes are evaluated at the same time.
X
Are temperature
uniformity surveys
performed per
requirements in Process
Tables?
Temperature uniformity surveys shall be conducted
per the requirements in the applicable Process
Tables, Section 2.0. The frequency reductions
allowed in AMS 2750D are not allowed under this
document. Certain furnace designs, e.g., rotary retorts
preclude direct temperature profiles. Alternate test
methods per AMS 2750D 3.5.15 are acceptable for
furnaces where temperature uniformity studies are not
possible.
We use the ongoing capability studies to
assure ourselves that the equipment can
meet the requirements
X
3.5
Is the variation of the
furnace controlled
thermocouple from set
point within the
requirements in the
Process Table?
The variation between the furnace-control
thermocouple and the set point temperature shall be
within the limits defined in the applicable Process
Tables, Section 2.0. This does not apply to the first
zone of a multi-zone continuous furnace.
Data collection program shows the
temperatures to be with-in the given range.
X
3.6
Are the process &
equipment alarm checks
being tested quarterly or
after any repair or
rebuild?
The heat treater shall have a list of heat treat process
and equipment alarms. These alarms shall be
independently tested quarterly at a minimum, and
after any repair or rebuild. These checks shall be
documented.
All alarms are posted at each piece of
equipment with a PM done quarterly to verify
all alarms.
X
CQI-9
Needs
Immediate
Action
Assessment
Generator and furnace atmosphere carbon
potential/dew point shall be continuously monitored,
automatically controlled, and documented. This
requirement is specific to Process Table 1, Sections
1.0 and 3.0, for carburizing, carbonitriding, and neutral
hardening. Continuous monitoring and automatic
control of the carbon potential/dew point is required
for all generators and atmosphere furnaces except
rotary retort and shaker furnaces that preclude in situ
control and monitoring. For rotary retort and shaker
furnaces, the method described in AMS 2750D
3.5.15..2 "Property Surveys" shall be used to ensure
adequate control of the furnace atmosphere. If
generators are not used, the flow rates of the supplied
atmosphere gases shall be monitored and controlled.
The assessor shall verify the effectiveness of the
atmosphere control system per customer
requirements, the heat treaters control plan, and
internal procedures. The atmosphere control system
shall maintain the atmosphere dew point/carbon
potential set point within the parameters specified in
the control plan or internal procedures. The heat
treater shall have a back-up method of checking the
carbon potential/dew point. Examples are dew point,
electrical wire resistance, gas analysist, shim stock,
carbon bar, etc. The automatic and continuous
atmosphere control systems shall consist of sensors
such as oxygen probes or on-line Infared (IR) gas
analysis. See Process Table A, Sect. 3.0 for
verification frequencies.
X 3.7
Are generators and
furnace atmospheres
continuously monitored,
automatically controlled,
and documented?
All furnaces are automatically controlled and
recorded. The carbon controllers are verified
by dew point daily. The generators are
monitored continuously and recorded.
CQI-9
Needs
Immediate
Action
Assessment
3.8
When the back-up
verification check of the
atmosphere does not
agree or correlate within
pre-established limits
with the primary control
method (carbon
potential/dew point
reading), is correlation of
the carbon-bearing
atmosphere to the
primary control method
re-established?
This issue is specific to Process Table 1, carburizing,
carbonitriding, and neutral hardening.
When the back-up verification check of the
atmosphere does not agree or correlate within pre-
established limits with the primary control method
(carbon potential/dew point reading), the heat treater
shall resolve the out-of-limit discrepancy. The back-
up atmosphere monitoring system reading and the
automatically controlled atmosphere dew point/carbon
potential reading shall be maintained within the
correlation limits specified in the control plan or
internal procedures. These range tolerances vary
with the specific heat treat process and the equipment
used.
The heat treater shall make appropriate technical
adjustments and corrections and then re-
establish/demonstrate the correlation of the actual
atmosphere carbon potential/dew point reading to the
primary control and back-up atmosphere reading.
The range tolerances for correlation between the two
readings shall be in the control plan or internal
procedures. The back-up carbon potential/dew point
reading shall be established using one or more of the
following methods:
Carbon bar or slug
Shim stock
3-gas analyzer
Dew point
Hot wire resistance
All back-up checks are recorded on the data
collection program and a maintenance work
order will record the problem and the
correction. The data collection program will
show the correlation between the two
readings.
X
CQI-9
Needs
Immediate
Action
Assessment
3.9
Are all ammonia lines
equipped with quick
disconnects or a three
valve fail safe vent
system?
All ammonia lines to furnaces shall be equipped with
quick disconnects or a three-valve fail-safe vent
system. Normal valves may allow ammonia to leak
through even when they are closed. This can be
undesirable and detrimental in heat treat processes
not specifying/requiring ammonia.
A quick disconnect shall be present in any ammonia
line going to a furnace. This line shall be
disconnected after carbonitriding (or any other
process using ammonia) before another heat treating
operation not specifying/using ammonia begins.
An alternative three-valve ammonia "fail-safe" vent
system is permitted. See the definition Three Valve
Fail-Safe Vent and diagram in the glossary.
Documentation shall show when ammonia lines are
disconnected for non-ammonia bearing atmosphere
processes.
All equipment with ammonia available have
quick disconnects installed and used. The
furnace log sheet will show the addition or
removal of the line.
X
3.10
For fasteners and small
metal parts, is a
minimum of 3 hours
allocated for an oxidizing
burn-out prior to
processing product not
requiring ammonia?
This is applicable to fasteners and small metal parts.
The heat treater shall perform a minimum 3 hours
oxidizing burn-out prior to processing product not
requiring ammonia as an addition. Ammonia pick-up
can be undesirable in parts and heat treat processes
not specifying/requiring ammonia as an addition. Log
book, data logger, or other records shall document the
actual oxidizing burn-out time and that sufficient time
has been allocated to remove ammonia from the
furnace prior to processing parts in heat treat
processes not specifying ammonia.
Procedure OI-008 instructs the operator to
have the ammonia off for 4 hrs prior to
running any neutral harding work.
X
CQI-9
Needs
Immediate
Action
Assessment
3.11
Do all atmosphere
furnaces and generators
have flow scopes or flow
meters for all gases?
All atmosphere furnaces and generators (output
trim/adjustment gas) shall have flow scopes or flow
meters for all gases. Flow scopes and meters shall
be periodically serviced per the heat treater's
preventive maintenance program. Cleaning and
proper re-assembly procedures shall be documented.
All furnaces and generators have flow scopes
for all gases.
X
3.12
For threaded fasteners,
are all continuous belt
furnaces equipped with
sight glass inspection
ports and infrared
pyrometers at discharge
end of the hardening
furnace?
Infrared temperature pyrometers are required at the
exit end of continuous belt furnaces running threaded
fasteners to monitor for under temperature parts. The
temperature alarm shall be within 28C (50F) of the
furnace set point temperature. Results shall be strip
charted or continuously data logged. Infrared (IR)
units shall be calibrated annually at a minimum and
certified. All sight glasses shall be cleaned per the
preventive maintenance schedule.
n/a
3.13
Is salt chemistry in the
austenitizing salt bath
monitored?
Applicable to ferritic-nitrocarburizing, austempering,
and neutral hardening in salt.
The heat treater shall check the salt chemistry in the
austentizing salt bath, or part decarburization, daily.
Refer to the applicable Process Tables, Section 3.0,
for frequency of checks.
n/a
3.14
Is the quenching
medium analyzed?
The heat treater shall periodically have the quenching
medium analyzed for specific quenching
characteristics, e.g., cooling curve, water content, salt
concentration, as specified in the applicable Process
Tables, Section 5.0.
The quench media characteristic tolerances shall be
specified by the quench medium supplier or the heat
treater.
Analysis shall be reviewed for conformance by the
heat treater. This review shall be documented.
All furnaces have the quenchant checked by
an outside lab 4 times per year.
X
3.15
Is the position of each
part being controlled?
A method to detect proper part position, such as the
use of proximity switches, optical sensors, mechanical
probes, etc., is required for each part.
Either a scanner with optical sensors or
specific fixtures are used to assure that parts
are properly located.
X
FOR INDUCTION HEAT TREATING
CQI-9
Needs
Immediate
Action
Assessment
3.16
control the energy or
power for each part?
The heat treater shall control the energy or power for
each part.
A signature monitor for each machine is preferred.
A signature monitor gives the energy unit (voltage,
kilowatt, etc.) vs. time or distance (for scanning
systems).
An energy monitor or equivalent is acceptable if
approved by the authorized customer representative.
Each machine has a power setting control. X
3.17
Does the supplier have
a coil management
system? Coil refers to
the heating coil and the
quench plenum.
The heat treater shall have a coil management
system. Coil refers to the heating coil and the quench
plenum.
Spare coils for each part shall be available on-site.
Coils shall conform to the approved original design.
Engineering change approval from the customer is
required whenever the coil design is changed.
Each coil is ID'd and tied to the part with a
set-up instruction.
X
3.18
Is quench system
automatic?
The quench system shall be an automatic operation.
No manual quenching is allowed unless specifically
approved by the authorized customer representative.
Quenching shall be automatically initiated and
controlled.
All equipment has automatic quench on and
timers for duration.
X
3.19
Does each lot of parts
have first piece set-up?
The heat treater shall perform first piece set-up for
each lot of parts
Each job has a set-up instruction and first
piece inspection.
X
CQI-9
Section 4 - Job Audit
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Heat Treat Requirements:
Question # J ob Audit Question
Related
HTSA Question #
Customer or Internal
Requirement
J ob (Shop) Order or
Reference Documentation
Requirement
Actual Condition
(Objective Evidence)
Pass / Fail
/ N/A
4.1 Are contract review, advance
quality planning, FMEA, control
plans, etc., performed by qualified
individuals?
1.2
1.3
1.4
1.17
YES N/A Incoming P.O
PASS
4.2
Does the heat treat facility have the
customer specifications for the
part?
1.5 YES N/A Print PASS
4.3
Is a shop traveler created to meet
customer requirements?
1.6
2.1
YES 323038 PASS
4.4 Is material identification (part
numbers, lot numbers, heat
numbers, contract numbers, etc.)
maintained throughout the heat
treat process?
2.2
2.3
2.4
YES CSP#109 PASS
4.5 Is there documented evidence of
Receiving Inspection?
2.1 YES P.O. #0014729 Highlighted PASS
4.6
Are the Loading / Racking
requirements identified?
1.6
2.7
2.9
YES Rack RI-404 PASS
4.7 Is the proper recipe or process
specification (cycle times,
temperature, atmosphere, etc.)
used? Refer to Process Tables,
Section 3.0, for specific
parameters. List parameters that
were verified in this audit in the
spaces provided below.
1.5
1.6
2.1
2.14
2.15
YES 323038 Furnace Log
P62-2/23/11
PASS
Furnace Temperature 4.7 1700/1600
Quench Type 4.7 High Oil 323038 Furnace PASS
Carbon 4.7 95C. Log
Draw Temperature 4.7 300'f
BIL-MAC
323038
GR030
SHAFT
8620
.035-.045 EFF/ RA 78.5MIN. / RC 25-45 CORE
CQI-9
Related
HTSA Question #
Requirement
Requirement
Actual Condition
Pass / Fail
/ N/A
4.8 What are the product inspection
requirements?
2.15 PASS
4.8.1 Requirement: (1) As quenched
Test Method: Rockwell A core RC
Test frequency or quantity: 1pc 1st loas/Every 4hr 323038 Surface RA 80,81,82 PASS
Selection of samples: Random Core RC 40-42-42
Specification: RA 78.5 min/ core rc 25-45
4.8.2 Requirement: (2) mount/lab f2-5-11 .044 eff PASS
Test Method: Knoop Core RC 45
Test frequency or quantity: 1 pc per order
Selection of samples: Random
Specification: Core RC 25-45 .035-.045 eff case
4.8.3 Requirement: (3) After Temper
Test Method: RA-surface RC core 323038 rc 43,43,44 PASS
Test frequency or quantity: 3 pcs per order RA 81,82,83
Specification: RA 78.5 / RC 25-45
4.8.4 Requirement: (4)
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
4.9 Were appropriate process steps
signed off?
1.4
2.2
2.3
2.14
323038 YES PASS
4.10 Were all inspection steps, as
documented in the control plan
performed?
1.2
1.4
323038 YES PASS
4.11
Were steps/operations performed
that were not documented in the
control plan?
1.2
1.4
1.6
NO PASS
4.12 If additional steps were performed,
were they authorized?
1.2
1.4
1.6
1.11
1.17
4.13
Does the governing specification
allow reprocessing or rework?
1.11 YES PASS
4.14
If the order was certified, did the
certification accurately reflect the
process performed?
2.14
2.15
323038 YES PASS
4.15
Was the certification signed by an
authorized individual?
1.17 323038 YES PASS
RA 78.5 MIN. .035-.045 EFF CORE RC 25-45
Operator or Inspector Responsibilities
CQI-9
Related
HTSA Question #
Requirement
Requirement
Actual Condition
Pass / Fail
/ N/A
4.16 Are the parts and containers free of
inappropriate objects or
contamination?
2.6
2.11
Visual YES PASS
Packaging Requirements
4.17
Are packaging requirements
identified?
2.9 323038 24 Pans PASS
4.18
Are parts packaged to minimize
mixed parts (for example, parts
packed over height of container)?
2.9 Visual Stacked neatly PASS
Shipping Requirements
4.19 Were the parts properly identified? 2.3
2.9
323038 YES PASS
4.20
Were the containers properly
labeled?
2.3
2.9
CSP #109 YES PASS
CQI-9
Section 4 - Job Audit
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Heat Treat Requirements:
Related
HTSA Question #
Requirement
Requirement
Actual Condition
Pass / Fail
/ N/A
4.1 Are contract review, advance
quality planning, FMEA, control
plans, etc., performed by qualified
individuals?
1.2
1.3
1.4
1.17
N/A Incoming P.O
PASS
4.2
Does the heat treat facility have the
customer specifications for the
part?
1.5 N/A Print PASS
4.3
Is a shop traveler created to meet
customer requirements?
1.6
2.1
323613 PASS
4.4 Is material identification (part
numbers, lot numbers, heat
numbers, contract numbers, etc.)
maintained throughout the heat
treat process?
2.2
2.3
2.4
CSP#21 PASS
4.5 Is there documented evidence of
Receiving Inspection?
2.1 PO#44969 Highlighted PASS
4.6
Are the Loading / Racking
requirements identified?
1.6
2.7
2.9
323613 Hand Load PASS
4.7 Is the proper recipe or process
specification (cycle times,
temperature, atmosphere, etc.)
used? Refer to Process Tables,
Section 3.0, for specific
parameters. List parameters that
were verified in this audit in the
spaces provided below.
1.5
1.6
2.1
2.14
2.15
323613 Log Sheet PASS
TEMPERATURE 1650' F
QUENCH TYPE OIL QUENCH SAME
TEMPER TEMPERATURE 950' F
Williams Form
323613
Hex Nuts 2 1/2"
Nut
1045
RC 25-38
CQI-9
4.8 What are the product inspection
requirements?
2.15 PASS
4.8.1 Requirement: (1) Surf
Test Method: RC 25-35
Test frequency or quantity: 1 PC 1ST LOAD/EVERY 4 HR SAME RC 56,57,58 PASS
Specification:
4.8.2 Requirement: (2) AFTER TEMPER
Test Method: ROCKWELL C
Test frequency or quantity: 3 PER ORDER SAME RC 32,24,36 PASS
Selection of samples: RANDOM
Specification: RC 25-35
Test Method:
Specification:
Test Method:
Specification:
4.9 Were appropriate process steps
signed off?
1.4
2.2
2.3
2.14
YES 323613 YES PASS
4.10 Were all inspection steps, as
documented in the control plan
performed?
1.2
1.4
323613 YES PASS
4.11
Were steps/operations performed
that were not documented in the
control plan?
1.2
1.4
1.6
NO PASS
4.12 If additional steps were performed,
were they authorized?
1.2
1.4
1.6
1.11
1.17
4.13
Does the governing specification
allow reprocessing or rework?
1.11 YES PASS
4.14
If the order was certified, did the
certification accurately reflect the
process performed?
2.14
2.15
323613 YES PASS
4.15
Was the certification signed by an
authorized individual?
1.17 323613 YES PASS
4.16 Are the parts and containers free of
inappropriate objects or
contamination?
2.6
2.11
Visual YES PASS
Packaging Requirements
RC 25-35
Operator or Inspector Responsibilities
CQI-9
4.17
Are packaging requirements
identified?
2.9 323613 1 BASKET PASS
4.18
Are parts packaged to minimize
mixed parts (for example, parts
packed over height of container)?
2.9 Visual STACKED PASS
Shipping Requirements
4.19 Were the parts properly identified? 2.3
2.9
323613 Yes PASS
4.20
Were the containers properly
labeled?
2.3
2.9
323613 Yes PASS
CQI-9
Item # Related HTSA
Question #
Category/Process Steps Batch
Furnace
Continuous
Furnace *
Generators
1.0 PROCESS AND TEST EQUIPMENT REQUIREMENTS
A1.1 3.1
3.7
All furnaces, generators and quench systems shall have
temperature indicating instruments.
Yes Yes Yes
A1.2 3.1
3.7
Continuous strip charts and/or data loggers are required for
temperature and carbon monitoring unit, e.g., dew point,
oxygen probe, IR gas analyzer, etc.
Yes Yes Yes
A1.3 1.18 A program for furnace and generator burnout is required
(applies to carbon bearing atmospheres).
Yes Yes Yes
A1.4 3.2 Furnace weigh scales shall be verified quarterly and calibrated
annually at a minimum.
Yes Yes -----
A1.5 3.2 Dew pointers, 3-gas analyzers, spectrometers, and carbon IR
combustion analyzers (shim stock analysis), used to verify
carbon potential in furnaces, shall be calibrated annually at a
minimum.
----- ----- -----
A1.6 3.2 Verification of calibration of spectrometers, and carbon IR
combustion analyzers, shall be checked daily or prior to use.
----- ----- -----
A1.7 3.2 Verification of calibration of 3-gas analyzers with zero gas and
span gas shall be performed weekly at a minimum.
----- ----- -----
A1.8 3.2 Oxygen probe controllers shall be calibrated quarterly at a
minimum.
Yes Yes Yes
A1.9 2.16 All hardness test equipment (for each scale used) shall be
calibrated semi-annually minimum, and verified daily minimum
per the applicable ASTM standard.
----- ----- -----
A1.10 2.16 Files shall be verified daily (or prior to use) with provers per
SAE J 864.
----- ----- -----
A1.11 3.2 Refractometers (typically used to check polymer quenchants
and washer solutions) shall be verified daily (with distilled
water) and calibrated annually (per manufacturer's
requirements) at a minimum.
----- ----- -----
PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering /
Martempering / Tempering / Precipitation Hardening - Aging
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 heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
** Does not apply to furnaces operating below 760C (1400F).
----- indicate " not applicable" .
CQI-9
Item # Related HTSA
Question #
Furnace
Continuous
Furnace *
Generators
2.0 PYROMETRY
A2.1 3.2
3.3
Thermocouples and calibration of thermocouples shall
conform to AMS 2750D.
Yes Yes Yes
A2.2 3.2
3.3
Instrument Calibration per AMS 2750D shall be quarterly at a
minimum.
Frequency reductions per AMS 2750D are not allowed.
Yes Yes Yes
A2.3 3.2
3.3
CQI-9 requires a comparative check of the control
temperature sensor (CTS) in the Qualified Work Zone to a (1)
calibrated test temperature sensor (CTTS) or, (2) resident
thermocouple (R-T/C). (1) The CTS shall be within an
operating temperature range of +/- 5C (or +/-10F) of the
CTTS. This check shall be performed monthly. (2) Within the
operating temperature range the difference between the CTS
and R-T/C readings shall be no more than +/- 1C (or +/-2F) as
determined at the time of the most recent temperature
uniformity survey. This check shall be performed weekly. Any
actions to correct a failing reading or validate a test result shall
be documented. Additionally, Type K and N thermocouples
shall be checked monthly for equipment operating at or above
760C (1400F) and changed annually at a minimum. Type K
and N thermocouples shall be checked quarterly for
equipment operating below 760C (1400F) and changed every
two years at a minimum.
Yes Yes Yes
Type R and S thermocouples shall be checked monthly for
equipment operating at or above 760C (1400F) and changed
every two years at a minimum. Protection Tubes shall be
visually checked at the same frequency as thermocouples.
A2.4 3.4 Temperature Uniformity Survey (TUS): refer to AMS 2750D for
procedures. TUS frequency shall be annual and after major
rebuild.
Temperature uniformity tolerance for hardening furnaces shall
be +/- 14 C (or +/- 25 F). Temperature uniformity tolerance for
tempering furnaces shall be +/- 11 C (or +/- 20 F).
Minimum and maximum temperature ranges shall be tested
per AMS 2750D. Exception: If the operating range of the
Qualified Work Zone is equal to or less than 85 C (153 F) then
only one temperature is required to be tested. The
temperature shall be within the operating range of the
Qualified Work Zone.
Yes Yes - In Qualified Work
Zone
-----
A2.5 3.5 Recorded temperature(s) for austentizing processes shall be
controlled within +/- 9C (or +/- 15F) of the set point as
evidenced by continuous recording pyrometers. Furnace
temperature shall be controlled with soak times starting at the
lower tolerance limit (as defined above).
Zone
-----
CQI-9
Item # Related HTSA
Question #
Furnace
Continuous
Furnace *
Generators
A2.6 3.5 Recorded temperature(s) for tempering and precipitation
hardening processes shall be controlled within +/- 6C (or +/-
10F) of the set point as evidenced by continuous recording
pyrometers. Furnace temperature shall be controlled with
soak times starting at the lower tolerance limit (as defined
above).
Zone
-----
A2.7 3.2 Infrared pyrometers shall be calibrated to a black body furnace
annually.
-----
CQI-9
Item # Related HTSA
Question #
Furnace
Continuous
Furnace *
Generators
3.0 PROCESS MONITOR FREQUENCIES
A3.1 1.4
2.14
Monitor primary temperature control instrument(s). Each batch or
continuous recording
with sign-off every 2
hours. Alarm systems
satisfy the sign-off
requirement.
Each lot or continuous
recording with sign-off
every 2 hours. Alarm
systems satisfy the sign-
off requirement
Each Shift
A3.2 1.4
2.14
3.7
Monitor generator atmospheres. ----- ----- Continuous
A3.3 1.4
2.14
3.7
Monitor primary furnace atmosphere control(s)**. Continuous recording
requirement.
Continuous recording
requirement
-----
A3.4 1.4
2.14
3.7
Verify primary atmosphere control method by back-up
method**.
Daily Daily Daily
A3.5 1.4
2.14
3.13
For austentizing salt baths: Salt chemistry (soluble oxides) or
decarburization on the parts shall be checked daily.
Daily Daily -----
Quench Media Process Parameters
- Temperature Each batch or
requirement.
off requirement.
-----
- Quench Level Daily Daily -----
- Agitation - Daily visual check is
required.
- Monitor each load in
the absence of an
alarm system.
- Daily visual check is
required.
- Monitor every 2 hours
in the absence of an
alarm system.
-----
A3.7 1.4
2.14
Monitor time in furnace, cycle time or belt speed. Each batch Twice/shift & after any
change in the belt
speed.
-----
A3.8 1.4
2.7
Monitor load size or fixturing or loading rate as applicable. Each batch Twice/shift & after any
change in loading rate.
-----
A3.9 1.4
2.12
Quench Delay Time -
Alarm system shall be based on the time that the load exits
the furnace to the time the load is at the bottom of the quench
tank.
Each batch Each basket for pusher-
type continuous
furnaces. Not applicable
for belt furnaces.
-----
A3.6 1.4
2.12
CQI-9
Item # Related HTSA
Question #
Furnace
Continuous
Furnace *
Generators
4.0 IN-PROCESS/FINAL TEST FREQUENCIES
A4.1 1.4
2.15
Microstructure Daily per furnace Daily per furnace -----
A4.2 1.4
2.15
Surface hardness Each batch Every 2 hours minimum -----
A4.3 1.4
2.15
Core hardness (when specified) Each batch Every 4 hours -----
A4.4 1.4
2.15
Case depth (when specified) Each batch Every 4 hours -----
5.0 QUENCHANT AND SOLUTION TEST FREQUENCIES
Polymer Quench Media
- Concentration Daily Daily -----
- Quenchability Check; e.g., cooling curve, viscosity, or
titration
Every six months Every six months -----
Water Quench Media
- Suspended solids Every six months Every six months -----
Salt Quench Media
- Analysis & Contaminants Every six months Every six months -----
Brine or Caustic Quench Media
- Concentration and/or Specific
Gravity.
Daily Daily -----
Oil Quench Media
- Water content, suspended solids,
viscosity, cooling curve, total acid,
and flash point.
Quarterly Quarterly -----
Rust Preventive - Soluble Oil
- Concentration 2x / week 2x / week -----
Washers
- Concentration of cleaner Daily Daily -----
- Temperature of solution (required if temperature is specified
to be above ambient temperature).
Each shift Each shift -----
2.12
3.14
2.12
3.14
2.12
3.14
A5.1
A5.2
A5.3
A5.4
2.12
3.14
A5.5
A5.6
A5.7 2.11
2.13
2.12
3.14
CQI-9
Item # Related
HTSA
Question #
Furnace
Continuous
Furnace*
Generators Salt Bath
1.0 PROCESS AND TEST EQUIPMENT
REQUIREMENTS
B1.1 3.1
3.7
All furnaces, generators and quench systems shall
have temperature indicating instruments.
Yes Yes Yes Yes
B1.2 3.1
3.7
Continuous strip charts and/or data loggers are
required for temperature and carbon monitoring unit,
e.g., dew point, oxygen probe, IR gas analyzer, etc.
Yes Yes Yes Yes -
For
temperature
only
B1.3 1.18 A program for furnace and generator burnout is
required. Not required for retort gas nitriding.
Yes Yes Yes -----
B1.4 3.12
3.13
For austentizing salt baths: Salt chemistry (soluble
oxides) or decarburization on the parts shall be
checked daily.
----- ----- ----- Yes
B1.5 3.2 Furnace weigh scales shall be verified quarterly and
calibrated annually at a minimum.
Yes Yes ----- -----
B1.6 3.2 Dew pointers and gas analyzers, used to verify proper
atmosphere in furnaces, shall be calibrated annually
at a minimum.
----- ----- ----- -----
B1.7 2.16 All hardness test equipment (for each scale used)
shall be calibrated semi-annually minimum, and
verified daily minimum per the applicable ASTM
standard.
----- ----- ----- -----
B1.8 2.16 Files shall be verified daily (or prior to use) with
provers per SAE J 864.
----- ----- ----- -----
B1.9 3.2 Refractometers (typically used to check polymer
quenchants and washer solutions) shall be verified
daily (with distilled water) and calibrated annually (per
manufacturer's requirements) at a minimum.
----- ----- ----- -----
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify heat treater is conforming to the customer's requirements.
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
CQI-9
Item # Related
HTSA
Question #
Furnace
Continuous
Furnace*
2.0 PYROMETRY
B2.1 3.2
3.3
Yes Yes Yes Yes
B2.2 3.2
3.3
Instrument Calibration per AMS 2750D shall be
quarterly at a minimum.
Frequency reductions per AMS 2750D are not
allowed.
Yes Yes Yes Yes
B2.3 3.2
3.3
temperature sensor (CTS) in the Qualified Work Zone
to a (1) calibrated test temperature sensor (CTTS) or,
(2) resident thermocouple (R-T/C).
(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at
the operating temperature range; this checked shall
be performed monthly.
(2) The relationship between the CTS and R-T/C at
the operating temperature range shall be within +/- 1C
(or +/- 2F) of their relationship determined at the time
of the most recent temperature uniformity survey; this
checked shall be performed weekly.
Any actions to correct a failing reading or validate a
test result shall be documented.
Additionally, Type K and N thermocouples shall be
checked monthly for equipment operating at or above
760C (1400F) and changed annually at a minimum.
Type K and N thermocouples shall be checked
quarterly for equipment operating below 760C (1400F)
and changed every two years at a minimum.
Yes Yes Yes Yes
Type R and S thermocouples shall be checked
monthly for equipment operating at or above 760C
(1400F) and changed every two years at a minimum.
Protection Tubes shall be visually checked at
same frequency as thermocouples.
CQI-9
Item # Related
HTSA
Question #
Furnace
Continuous
Furnace*
B2.4 3.4 Temperature Uniformity Survey (TUS): refer to AMS
2750D for procedures. TUS frequency shall be annual
and after major rebuild.
Temperature uniformity tolerance shall be +/- 9 C (15
F).
Minimum and maximum temperature ranges shall be
tested per AMS 2750D. Exception: If the operating
range of the Qualified Work Zone is equal to or less
than 85 C (153 F) then only one temperature is
required to be tested. The temperature shall be within
the operating range of the Qualified Work Zone.
Frequency reductions per AMS 2750D are not
allowed.
Yes Yes - In Qualified
Work Zone
----- Yes
B2.5 3.5 Recorded temperature(s) shall be controlled within +/-
9C (or +/- 15F) of the set point as evidenced by
continuous recording pyrometers. Furnace
temperature shall be controlled with soak times
starting at the lower tolerance limit (as defined above).
Yes Yes - In Qualified
Work Zone
----- Yes
B2.6 3.2 Infrared pyrometers shall be calibrated to a black
body furnace annually .
CQI-9
Item # Related
HTSA
Question #
Furnace
Continuous
Furnace*
B3.1 1.4
2.14
continuous
recording with
sign-off every
2 hours.
Alarm
systems
satisfy the
sign-off
requirement
Each lot or
continuous
recording with
sign-off every 2
hours. Alarm
systems satisfy
the sign-off
requirement
Each Shift Every 2 hours
& after any
change
B3.2 1.4
2.14
3.7
Monitor generator atmospheres, if applicable. ----- ----- Continuous -----
B3.3 1.4
2.14
3.7
Monitor primary furnace atmosphere control(s). Each batch
(rotary
furnaces only)
or continuous
recording with
sign-off every
2 hours.
Alarm
systems
satisfy the
sign-off
requirement
Continuous
recording with
sign-off every 2
hours. Alarm
systems satisfy
the sign-off
requirement
----- Daily
B3.4 1.4
3.7
Dissociation of ammonia shall be checked in gas
nitriding.
Each batch
and every 4
hours
minimum
Every 4 hours Daily N/A
B3.5 1.4
3.7
Gas ratios for ferritic nitrocarburizing shall be
checked.
Each batch Every 2 hours
minimum
B3.6 1.4
2.14
3.13
Check salt chemistry (soluble oxides) in salt baths
used for austenitizing, or decarburization on the parts.
----- ----- ----- Daily
CQI-9
Item # Related
HTSA
Question #
Furnace
Continuous
Furnace*
- Temperature Each batch or
continuous
recording with
sign-off every
2 hours.
Alarm
systems
satisfy the
sign-off
requirement.
Each lot or
continuous
recording with
sign-off every 2
hours. Alarm
systems satisfy
the sign-off
requirement.
----- Each batch or
continuous
recording with
sign-off every
2 hours.
Alarm systems
satisfy the
sign-off
requirement.
- Quench Level Daily Daily ----- Daily
- Agitation - Daily
- Monitor
each load in
the absence
of an alarm
system.
- Daily
- Monitor every 2
hours in the
absence of an
alarm system.
----- Daily
B3.8 1.4
2.14
Monitor time in furnace, cycle time or belt speed. Each batch Twice/shift &
after any change
in the belt speed.
----- Each batch
B3.9 1.4
2.7
Monitor load size or fixturing or loading rate as
applicable.
Each batch Twice/shift &
after any change
in loading rate.
----- Each batch
B3.10 1.4
2.12
Quench Delay Time if applicable -
Alarm system shall be based on the time that the load
exits the furnace to the time the load is at the bottom
of the quench tank.
Each batch Each basket if
applicable.
----- Each batch
B4.1 1.4
2.15
Microstructure Daily per
furnace
Daily per furnace ----- Daily per
furnace
B4.2 1.4
2.15
Surface hardness Each batch Every 2 hours
minimum
----- Each batch
B4.3 1.4
2.15
Core hardness (when specified) Each batch Every 4 hours ----- Each batch
B4.4 1.4
2.15
Case depth (when specified) Each batch Every 4 hours ----- Each batch
B3.7 1.4
2.12
CQI-9
Item # Related
HTSA
Question #
Furnace
Continuous
Furnace*
5.0 QUENCHANT AND SOLUTION TEST
FREQUENCIES
Quench Media Controls If Applicable
- Concentration Daily Daily ----- -----
- Quenchability Check; e.g., cooling
curve, viscosity, or titration.
Every six
months
Every six months ----- -----
Water Quench Media
- Suspended solids Every six
months
Salt Quench Media
- Analysis & Contaminants Every six
months
Every six months ----- Every six
months
Gravity
Daily Daily ----- -----
- Suspended solids Every six
months
Oil Quench Media
- Water content, suspended solids,
viscosity, cooling curve, total acid,
and flash point.
Quarterly Quarterly ----- -----
- Concentration 2x / week 2x / week ----- 2x / week
Washers
- Concentration of cleaner Daily Daily ----- Daily
- Temperature of solution (required if temperature is
specified to be above ambient temperature).
Each shift Each shift ----- Each shift
B5.5
B5.6
B5.1
B5.2
B5.4
B5.7
2.12
3.14
2.12
3.14
2.12
3.14
2.12
3.14
2.13
2.11
2.12
3.14
B5.3
CQI-9
Item # Related
HTSA
Question #
Category/Process Steps Batch Solution Treating
and Aging Furnaces
Continuous Solution
Treating and Aging
Furnaces
Annealing
Furnace
REQUIREMENTS
C1.1 3.1
3.7
All furnaces and quench systems shall have
temperature indicating instruments.
Yes Yes Yes
C1.2 3.1
3.7
Continuous strip charts and/or data loggers are
required for temperature sensors.
Yes Yes Yes
C1.3 2.16 All hardness test equipment (for each scale used) shall
be calibrated semi-annually minimum, and verified
daily minimum per the applicable ASTM standard.
----- ----- -----
C1.4 3.2 Furnace weigh scales shall be verified quarterly and
Yes Yes Yes
C1.5 3.2 Refractometers (typically used to check polymer
quenchants and washer solutions) shall be verified
daily (with distilled water) and calibrated annually (per
manufacturer's requirements) at a minimum.
----- ----- -----
*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
PROCESS TABLE C - Aluminum Heat Treating
CQI-9
Item # Related
HTSA
Question #
and Aging Furnaces
Continuous Solution
Treating and Aging
Furnaces
Annealing
Furnace
2.0 PYROMETRY
C2.1 3.2
3.3
Yes Yes Yes
C2.2 3.2
3.3
Instrument Calibration per AMS 2750D shall be
quarterly at a minimum.
Yes Yes Yes
C2.3 3.2
3.3
temperature sensor (CTS) in the Qualified Work Zone
to a (1) calibrated test temperature sensor (CTTS) or,
(2) resident thermocouple (R-T/C).
(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at
the operating temperature range; this checked shall be
performed monthly.
(2) The relationship between the CTS and R-T/C at the
operating temperature range shall be within +/- 1C (or
+/- 2F) of their relationship determined at the time of
the last temperature uniformity survey; this checked
shall be performed weekly.
Any actions to correct a failing reading or validate a
test result shall be documented.
Type K and N thermocouples shall be checked
quarterly for equipment operating below 760C (1400F)
and changed every two years at a minimum.
Yes Yes Yes
Type R and S thermocouples shall be checked monthly
for equipment operating at or above 760C (1400F) and
changed bi-annually every two years at a minimum.
CQI-9
Item # Related
HTSA
Question #
and Aging Furnaces
Continuous Solution
Treating and Aging
Furnaces
Annealing
Furnace
C2.4 3.4 Temperature Uniformity Survey (TUS): refer to AMS
2750D for procedures. TUS frequency shall be
quarterly and after major rebuild.
Temperature uniformity tolerance for solution treating
and aging furnaces shall be +/- 6 C (or +/- 10 F).
Temperature uniformity tolerance for annealing
furnaces shall be +/- 14 C (or +/- 25 F).
tested per AMS 2750D. Exception: If the operating
range of the Qualified Work Zone is equal to or less
than 85 C (153 F) then only one temperature is
required to be tested. The temperature shall be within
the operating range of the Qualified Work Zone.
Zone
Yes
C2.5 3.5 Recorded temperature(s) shall be controlled within +/-
temperature shall be controlled with soak times starting
at the lower tolerance limit (as defined above).
Zone
-----
C2.6 3.5 Recorded temperature(s) shall be controlled within +/-
temperature shall be controlled with soak times starting
at the lower tolerance limit (as defined above).
----- ----- Yes
C2.7 3.2 Infrared pyrometers shall be calibrated to a black body
furnace annually.
CQI-9
Item # Related
HTSA
Question #
and Aging Furnaces
Continuous Solution
Treating and Aging
Furnaces
Annealing
Furnace
C3.1 1.4
2.14
Monitor primary temperature control instrument(s). Each batch or continuous
systems satisfy the sign-off
requirement.
off requirement.
Each batch or
continuous
recording with
sign-off every
2 hours.
Alarm
systems
satisfy the
sign-off
requirement.
- Heat treater shall specify temperature range based on
product form and material. Temperature shall be
monitored as noted.
Each batch or continuous
systems satisfy the sign-off
requirement.
off requirement.
-----
- Quench Level Daily Daily -----
- Agitation - Daily visual check is
required.
- Monitor each load in the
absence of an alarm
system.
- Daily visual check is
required.
- Monitor every 2 hours
in the absence of an
alarm system.
-----
C3.3 1.4
2.14
Monitor process cycle time Each batch Twice/shift & after any
change in the indexing
speed.
Each batch
C3.4 1.4
2.7
Monitor load size or fixturing as applicable. Each batch Twice/shift & after any
Each batch
C3.5 1.4
2.12
Quench Delay Time -
Quench delay time shall be based on the time that the
load exits the furnace to the time the load is at the
bottom of the quench tank.
Each batch Each load -----
C4.1 1.4
2.15
Hardness or tensile testing (post aging). Each batch Every 4 hours Each batch or
every 4 hours
for continuous
furnaces
5.0 QUENCHANT AND SOLUTION TEST FREQUENCIES
- Concentration Daily Daily -----
curve, viscosity, or titration.
Every six months Every six months -----
Water Quench Media
Washers
- Concentration of cleaner Daily Daily Daily
Each shift Each shift Each shift
C3.2 1.4
2.12
C5.3 2.11
2.12
3.14
2.12
3.14
C5.1
C5.2
CQI-9
Item # Related HTSA
Question #
Category/Process Steps Per Coil
REQUIREMENTS
D1.1 --- Per customer requirement
D1.2 2.16 All hardness test equipment (for each scale
used) shall be calibrated semi-annually
minimum, and verified daily minimum per
the applicable ASTM standard.
-----
D1.3 2.16 Files shall be verified daily (or prior to use)
with provers per SAE J 864.
-----
D1.4 3.2 Refractometers (typically used to check
polymer quenchants and washer solutions)
shall be verified each shift (with distilled
water) and calibrated annually (per
manufacturer's requirements) at a
minimum.
-----
PROCESS TABLE D - Induction Heat Treating
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc.
When performing the job audit, the auditor shall verify heat treater is conforming to the customer's
requirements.
CQI-9
Item # Related HTSA
Question #
requirements.
2.0 PYROMETRY
D2.1 3.2 Infrared pyrometers shall be calibrated to a
black body furnace annually.
-----
3.0 PROCESS MONITORING FREQUENCIES
- Temperature Alarm system for high and low
temperature is required.
- Quench Level Daily
- Quench Pressure and Flow - Quench pressure and flow may
checked at manifold. Quench
flow shall be checked visually at
each coil.
- In the absence of an alarm
system, monitor every 2 hours or
after any change.
D3.2 1.4
2.14
Monitor cycle time Check cycle time at start up and
after any process change.
D3.3 1.4
2.14
3.16
Monitor:
1) Volts or Amps, and
2) Kilowatts
Use of an energy monitor or signature
monitor satisfies 1) and 2).
- This requirement applies to
each power supply (not per coil).
- In the absence of an alarm
system, monitor every 2 hours or
after any change.
All process parameters shall be checked the beginning of every shift, tool change, or any equipment
repair. In absence of process parameter alarms, also check process parameters at end of shift or lot
(whichever is the greater frequency).
D3.1 1.4
2.12
CQI-9
Item # Related HTSA
Question #
requirements.
4.0 IN-PROCESS/FINAL TEST
FREQUENCIES
Production Setup or Coil Change -
Per Coil
(1st Piece Inspection)
D4.4 1.4
2.15
Induction pattern length 1 part at start-up, end of
production run, and every 4 hours
minimum, and 1 part pre and 1
part post tool change, equipment
repair, station alarm (shutdown,
malfunction, etc.)
D4.5 1.4
2.15
Total or Effective Case depth 1 part at start-up, end of
production run, and 1 part per 8
hours minimum, and 1 part pre
and 1 part post tool change,
equipment repair, station alarm
(shutdown, malfunction, etc.)
D4.6 1.4
2.15
Surface hardness 1 part at start-up, end of
malfunction, etc.)
D4.7 1.4
2.15
Core hardness (when specified) 1 part at start-up, end of
malfunction, etc.)
D4.8 1.4
2.15
Microstructure 1 part at start-up, and 1 part pre
and 1 part post tool change,
equipment repair, station alarm
(shutdown, malfunction, etc.)
CQI-9
Item # Related HTSA
Question #
requirements.
5.0 QUENCHANT AND SOLUTION TEST
FREQUENCIES
Quench Media Controls If Applicable
- Concentration Once per day
curve, viscosity, or titration
Monthly
Water Quench Media
- Suspended solids Quarterly
Gravity
Monthly
- Suspended solids Quarterly
- Concentration 2x / week
Washers
- Concentration of cleaner Daily
- Temperature of solution (required if
temperature is specified to be above
ambient temperature).
Each shift
D5.4
D5.5 2.11
2.13
2.12
3.14
D5.1
D5.2
D5.3 2.12
3.14
2.12
3.14
CQI-9
Item # Related HTSA
Question #
Furnace
Continuous
Furnace *
Generators
1.0 PROCESS AND TEST EQUIPMENT REQUIREMENTS
E1.1 3.1
3.7
All furnaces, generators and quench systems (where
applicable) shall have temperature indicating
instruments.
Yes Yes Yes
E1.2 3.1
3.7
Continuous strip charts and/or data loggers are required
for temperature and carbon monitoring unit, e.g., dew
point, oxygen probe, IR gas analyzer, etc.
Yes Yes Yes
E1.3 3.2 Furnace weigh scales shall be verified quarterly and
Yes Yes -----
E1.4 3.2 Dew pointers, 3-gas analyzers, spectrometers, and
carbon IR combustion analyzers (shim stock analysis),
used to verify carbon potential in furnaces, shall be
calibrated annually at a minimum. This is applicable
when used in controlling carbon-bearing atmospheres.
----- ----- -----
E1.5 3.2 Verification of calibration of spectrometers, and carbon
IR combustion analyzers, shall be checked daily or prior
to use. This is applicable when used in controlling
carbon-bearing atmospheres.
----- ----- -----
E1.6 3.2 Verification of calibration of 3-gas analyzers with zero
gas and span gas shall be performed weekly at a
minimum. This is applicable when used in controlling
----- ----- -----
E1.7 3.2 Oxygen probe controllers shall be calibrated quarterly at
a minimum. This is applicable when used in controlling
Yes Yes Yes
E1.8 2.16 All hardness test equipment (for each scale used) shall
be calibrated semi-annually minimum, and verified daily
minimum per the applicable ASTM standard.
----- ----- -----
PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving
CQI-9
Item # Related HTSA
Question #
Furnace
Continuous
Furnace *
Generators
2.0 PYROMETRY
E2.1 3.2
3.3
Yes Yes Yes
E2.2 3.2
3.3
Instrument Calibration per AMS 2750D shall be quarterly
at a minimum.
Yes Yes Yes
E2.3 3.2
3.3
temperature sensor (CTS) in the Qualified Work Zone to
a (1) calibrated test temperature sensor (CTTS) or, (2)
resident thermocouple (R-T/C).
(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the
operating temperature range; this checked shall be
performed monthly.
(2) The relationship between the CTS and R-T/C at the
operating temperature range shall be within +/- 1C (or +/-
2F) of their relationship determined at the time of the
most recent temperature uniformity survey; this checked
shall be performed weekly.
Any actions to correct a failing reading or validate a test
result shall be documented.
Type K and N thermocouples shall be checked quarterly
for equipment operating below 760C (1400F) and
changed every two years at a minimum.
Yes Yes Yes
Type R and S thermocouples shall be checked monthly
for equipment operating at or above 760C (1400F) and
changed bi-annually every two years at a minimum.
CQI-9
Item # Related HTSA
Question #
Furnace
Continuous
Furnace *
Generators
E2.4 3.4 Temperature Uniformity Survey (TUS): refer to AMS
2750D for procedures. TUS frequency shall be annual
and after major rebuild.
Temperature uniformity tolerance for hardening furnaces
shall be +/- 14 C (or +/- 25 F). Temperature uniformity
tolerance for tempering furnaces shall be +/- 11 C (or +/-
20 F).
tested per AMS 2750D. Exception: If the operating range
of the Qualified Work Zone is equal to or less than 85 C
(153 F) then only one temperature is required to be
tested. The temperature shall be within the operating
range of the Qualified Work Zone.
Zone
-----
E2.5 3.5 Recorded temperature(s) shall be controlled within +/-
continuous recording pyrometers. Furnace temperature
shall be controlled with soak times starting at the lower
tolerance limit (as defined above).
Zone
-----
CQI-9
Item # Related HTSA
Question #
Furnace
Continuous
Furnace *
Generators
E3.1 1.4
2.14
requirement.
off requirement.
Each Shift
E3.2 1.4
2.14
3.7
Monitor generator atmospheres ----- ----- Continuous
E3.3 1.4
2.14
3.7
Monitor primary furnace atmosphere control(s)**. Continuous recording
requirement.
Continuous recording
requirement.
-----
E3.4 1.4
2.14
3.7
Verify primary atmosphere control method by back-up
method**.
Daily Daily Daily
E3.5 1.4
2.14
3.13
For salt baths: check salt chemistry (soluble oxides) in
salt baths or decarburization on the parts.
Daily Daily -----
E3.6 1.4
2.14
Monitor time in furnace, cycle time or belt speed. Each batch Twice/shift & after any
change in the belt
speed.
-----
E3.7 1.4
2.7
Monitor load size or fixturing or loading rate as
applicable.
Each batch Twice/shift & after any
-----
E4.1 1.4
2.15
Microstructure (when specified) Daily per furnace Daily per furnace -----
E4.2 1.4
2.15
Surface hardness (when specified) Each batch Every 2 hours minimum -----
E4.3 1.4
2.15
Core hardness (when specified) Each batch Every 4 hours -----
5.0 SOLUTION TEST FREQUENCIES
- Concentration 2x / week 2x / week -----
Washers
- Concentration of cleaner Daily Daily -----
Each shift Each shift -----
E5.2 2.11
E5.1 2.13

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Special Process: Heat Treat System Assessment

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