Cqi 11

CQI-11
Special Process: Plating System Assessment

Version 3, Issued 9/19
Special Process: Plating System Assessment Cover SheetFacility Name: DeKalb Metal
FinishingAddress: 625 West 15th Street | PO Box 70 Auburn, IN 46706
Phone Number: 260.925.1820Current Quality Certification(s): IATF 16949:2016
Number of Plating Employees at this Facility: 54
Captive Plater (Y/N): NCommercial Plater (Y/N): Y
Date of Assessment: 7/1/2020Date of Previous Assessment: 1/1/2020Date of Re-

assessment (if necessary):
Type(s) of Plating Processing at this Facility:
Process Table A:Process Table F:
Zinc ✔Hard Chrome PlatingZinc Alloy Plating ✔
Process Table G:Process Table B:

Electroless NickelMechanical Plating
Process Table H:Process Table C:

Decorative Plating of Metal SubstratesHydrogen Embrittlement Relief Process
Process Table I:Process Table D:

Process Control and Testing Equipment Verification and CalibrationDecorative
Plating of Plastic Substrates
Process Table E:
Electropolish and Chrome Flash
Personnel Contacted:
Name: TitleCompanyPhoneEmailDave Houser Plant ManagerDMF260.925.1820, 116
dhouser@dekalbmetal.comPaul FryLab ManagerDMF260.925.1820, 115
pfry@dekalbmetal.comLarry SidleLab TechnicianDMF260.925.1820, 117
lsidle@dekalbmetal.comDrew RitchieQuality TechnicianDMF260.925.1820,
130dritchie@dekalbmetal.com
Auditors/Assessors:
Name: TitleCompanyPhoneEmailMatt Morris Compliance ManagerDMF260.925.1820,
114mmorris@dekalbmetal.comLori WestrickQuality ManagerDMF260.925.1820,
145lwestrick@dekalbmetal.com
Number of Nonconforming Findings from Section 1 and Section 2:0
Number of Nonconforming Findings in the Job Audit(s): 00
Number of Nonconforming Findings in the Process Table(s):0
© 2019 AIAG (Automotive Industry Action Group) 1

Section 1 - Management Responsibility & Quality PlanningThere shall be a dedicated
and qualified surface finishing person on site.
Objective EvidenceConformingNonconformingNALab ManagerConformingBusiness Plan and
Quality ManualConformingFORM DMF292ConformingBackground includes apprenticeship and
30+ years of practical
experience. ConformingEmployed since 1982ConformingYesConformingSection 1 -
Management Responsibility & Quality PlanningThe facility shall perform advanced
quality planning.
Objective EvidenceConformingNonconformingNAProcedure 14ConformingProcedure 14,
Procedure 11, DMF341ConformingProcedure 14ConformingSection 1 - Management
Responsibility & Quality PlanningThe facilities FMEAs shall be up to date and shall
reflect the current process.
1.1• To ensure readily available expertise, there shall be a dedicated and

qualified surface finishing person on site.
• This individual shall be a full-time employee and the position shall be reflected
in the organization chart.
• A job description shall exist identifying the qualifications for the position
including chemical and surface finishing/surface finishing knowledge.
• The qualifications shall include a minimum of 5 years’ experience in surface
finishing operation or a combination of a minimum of 5 years of relevant formal
education and surface finishing experience.
GuidanceWhat is this person’s title?
Is this position reflected in the organizational chart?
Is there a documented job description listing all the required qualifications and
responsibilities of this position?
Describe in detail this person’s educational background and practical experience.
How many years of process experience at a plating facility does this person have?
Is this individual a full-time employee at the location being audited?
Comments:
1.2• The organization shall incorporate a documented advanced product quality
planning process.
• A feasibility study shall be performed and internally approved for each new part
or process. Similar parts can be grouped into part families for this effort as
defined by the organization.
• After the part approval process is approved by the customer, no process changes
are allowed unless approved by the customer.
• The organization shall contact the customer when clarification of process changes
is required. This clarification of process changes shall be documented.
GuidanceDoes the facility use a documented advanced quality planning process?
Does the facility perform a documented internal feasibility study for each part
before processing?
If no, does the facility perform a documented internal feasibility study for
similar part types or family of parts before processing?
What is the procedure for changing the process after PPAP?
Comments:
1.3
Objective EvidenceConformingNonconformingNAPFMEA for each plating
lineConformingNames and job functions listed on FMEA'sConformingProcess
SpecificConformingYes, review FMEAs for evidenceConformingYes, review FMEAs for
evidenceConformingKCCConformingSee Revision Notes for EvidenceConformingSection 1 -
Management Responsibility & Quality PlanningThe process control plans shall be up
to date and shall reflect the current process.
Objective EvidenceConformingNonconformingNAControl Plan for each plating
lineConformingProcess SpecificConformingYes, review Control Plans for
evidenceConformingYes, review Control Plans for evidenceConformingNames and job
functions listed on Control PlansConformingYes, review Control Plans for
evidenceConformingYes, review Control Plan and Procedure 19 for evidenceConforming
• The organization shall incorporate the use of a documented Failure Mode and
Effects Analysis (FMEA) and ensure the FMEAs are updated to reflect current part
quality status.
• The FMEA shall be written for each part or part family or they may be process-
specific and written for each process.
• FMEAs shall address every process step from part receipt to part shipment.
• A cross-functional team shall be used in the development of the FMEA.
• All special characteristics, as defined by the organization and its customers,
shall be identified, defined, and addressed in the FMEA.
GuidanceDoes the facility have a documented Failure Mode and Effects Analysis
(FMEA) in use?
Identify the names and job function of the team members used in the development of
the FMEA.
Identify if the FMEA is written for each part, part family or process specific.
Are all FMEAs consistent with all associated documentation such as control plans,
work instructions and shop travelers?
Do all FMEAs include every process step from part receipt to part shipment?
Are special characteristics, as defined by the organization and its customers,
identified, defined, and addressed in the FMEAs?
Provide evidence that the FMEA has been updated in response to quality issues.
Comments:
1.4• The organization shall incorporate the use of a documented control plan and
ensure the control plans are updated to reflect current controls.
• The control plans shall be written for each part or part family or they may be
process-specific.
• The control plans shall address all process steps from part receipt to part
shipment and identify all equipment used and all key surface finishing process
parameters as defined by the organization.
• A cross-functional team shall be used in the development of control plans, which
shall be consistent with all associated documentation such as work instructions,
shop travelers, and FMEAs.
• All special characteristics, as defined by the organization and its customers,
shall be identified, defined, and addressed in the control plans.
• The control plan shall detail the product and process characteristics, and
controls including testing frequency and sample size.
GuidanceDoes the facility have a documented control plan in use?
Identify if the control plan is written for each part, part family or process
specific.
Do all control plans include every process step from part receipt to part shipment?
Does the control plan identify all key surface finishing process parameters?
Identify the names and job function of the team members used in the development of
the control plan.
Are the control plans consistent with all associated documentation such as work
instructions, shop travelers, specifications and
FMEAs?
Provide evidence that sample sizes and frequencies for evaluation of process and
product characteristics are addressed and
consistent with the minimum requirements.
KCCConformingSee Revision Notes for EvidenceConformingSection 1 - Management
Responsibility & Quality PlanningAll surface finishing related and referenced
specifications shall be up to date and available.
For example: SAE, AIAG, ASTM, General Motors, Ford, FCA, Toyota, Volvo Truck.
Objective EvidenceConformingNonconformingNASurface Finishing standards and customer
reference standards are
available electronically in a document management system.ConformingIHS Global,
Customer Portals, Customer CommunicationConformingUpdate notifications are sent
from IHS and some Customer Portals.
The rest are reviewed once their assigned validity date has expired
(typically 1 year)
ConformingMatt Morris (Manager) or Lori Westrick (Quality Manager) review all
obtained standards, notates applicable changes, loads them into a
document management/notification system and schedules QMS
updates as needed.
ConformingSection 1 - Management Responsibility & Quality PlanningThere shall be
documented process instructions.
Objective EvidenceConformingNonconformingNA
Are special characteristics, as defined by the organization and its customers,

identified, defined, and addressed in the control
plans?
Provide evidence that the control plan has been updated in response to quality
issues, customer requirements and process
changes.
Comments:
1.5A document control system is pertinent for the handling and internal
distribution of received customer specifications and to keep up to date with
national or global standards related to surface finishing processes. To
ensure all customer requirements are understood and satisfied, the organization
shall have all related surface finishing and customer referenced standards and
specifications available for use and a process to ensure
that they are current.
• The organization shall have a process to ensure the timely review, distribution,
and implementation of all customer and industry engineering standards and
specifications and changes based on customer-required
schedule. This process shall be executed as soon as possible and shall not exceed
two weeks.
• The organization shall document this process of review and implementation, and it
shall address how customer and industry documents are obtained, how they are
maintained within the organization, how the current
status is established, and how the relevant information is cascaded to the shop
floor within the two-week period.
• The organization shall identify who is responsible for performing these tasks.
GuidanceDoes the organization have all related surface finishing and customer
referenced standards and specifications available for use?
How are standards and specifications obtained?
Describe the system and timing used to maintain the standards and specifications to
ensure that they are up to date.
Define that process used to review and communicate within the two-week period
updated standards and specifications
throughout the organization. Include the names and job functions of the responsible
personnel.
Comments:
1.6• The organization shall have written process instructions for all active parts
or family of parts, including relevant part specific requirements. Examples of part
specific requirements include process line, plating type, load
size, rectifier settings, etc.
• These process instructions may take the form of work instructions, job card,
computer-based recipes, or other similar documents.
Guidance
FORM DMF147ConformingWork Instructions, Computer based recipesConformingSection 1 -
Management Responsibility & Quality PlanningA valid product capability study shall
be performed.
Objective EvidenceConformingNonconformingNALine Validation Documentation, PPAPs,
Corrosion ReportsConformingProcedure 28ConformingNo recent relocations, rebuilds,
or changes to process chemistryConformingProcedure 10ConformingProcedure
29ConformingSection 1 - Management Responsibility & Quality PlanningThe
organization shall collect, analyze, and react to product and process data over
time.
Objective EvidenceConformingNonconformingNASee Procedure 28, SPC Module and ERP
System for EvidenceConformingIntegrated into Management ReviewConformingExamples
include updates to maintenace schedules and the addition
of new process monitoring equipment.Conforming
Does the organization have written process instructions for all active parts or
family of parts and include all relevant operating
parameters?
What form of process specification is used?
(These may be in the form of work instructions, job card, computer-based recipes,
or other similar documents.)
Comments:
1.7To demonstrate each process is capable of yielding acceptable product, the
organization shall perform product capability studies for the initial validation of
each process, after relocation of any process equipment, and
after a major change of any process or equipment. The organization shall define
what constitutes a major change.
• Initial product capability studies shall be conducted for all surface finishing
processes per line as defined in scope of work and in accordance with customer
requirements. Capability study techniques shall be
appropriate for the surface finishing product characteristics, (e.g., surface
finishing thickness, corrosion resistance, etc.).
• An action plan shall exist to address the steps to be followed in case capability
indices fall outside customer requirements or established ranges.
GuidanceHas an initial product capability study been performed?
Are studies conducted for each surface finishing process for each line in the
facility?
Has a new study been completed after relocation of any process equipment, major
rebuild of any equipment, or any significant
change in process chemistry?
How does the organization define what constitutes a major change?
What steps are followed when capability indices fall outside specified
requirements?
Comments:
1.8• The analysis of product characteristics and processes parameters over time can
yield vital information for defect prevention efforts.
• Methods of analysis shall include ongoing trend or historical data analysis of
special product and process parameters.
• The organization shall determine which parameters to include in such analysis.
GuidanceWhat product characteristics and process parameters are used?
How is the ongoing trend or historical data reviewed and analyzed?
How does the organization use this data to prevent future failures and improve the
quality system?
Comments:
Section 1 - Management Responsibility & Quality PlanningAll process control and
testing records must be retained for a minimum of one calendar year after the year
in which they were created.
Objective EvidenceConformingNonconformingNAProcedure 01ConformingRetention limits
specified in CSR's are alligned with internal record
retention limits within Procedure 01. ConformingSection 1 - Management
Responsibility & Quality PlanningThere shall be a process in place to review the
monitoring systems/logs at specified intervals.
Objective EvidenceConformingNonconformingNAProcedure 25 and FORM DMF118, Management
ReviewConformingDrew RitchieConformingNo parts require Hydrogen Embrittlement
bakingN/AProcedure 25, Control PlansConformingSection 1 - Management Responsibility
& Quality PlanningInternal assessments shall be completed at a minimum once every
12 months using the latest revision of the CQI-11 Plating System Assessment.
Objective EvidenceConformingNonconformingNAhttps://dekalbmetal.com/wp-
content/uploads/2016/08/CQI11.pdfConformingSection 1 - Management Responsibility &
Quality PlanningThere shall be an internal system in place to authorize
reprocessing and it shall be documented.
1.9GuidanceWhat is the process to retain these records?

What is the process for retention of customer specific documents with longer
retention times?
Comments:
1.10• Management or management designee shall review the monitoring systems/logs at
specified intervals.
• In the case of Hydrogen Embrittlement avoidance and relief, review shall occur
prior to parts being released for shipment and shall not exceed 24 hours.
• The organization shall have reaction plans for nonconformances to process
requirements.
GuidanceDefine the process in place to gather and review this information.
Identify the manager or management designee reviewing the process records from the
monitoring systems/logs.
In the case of Hydrogen Embrittlement baking, is the review taking place within the
24 hour period?
Describe reaction plans for nonconformances to the written process requirements.
Comments:
1.11GuidanceWhat is the date of the last AIAG CQI-11 Plating System Assessment?
Comments:
1.12
Objective EvidenceConformingNonconformingNAProcedure 29ConformingProcedure
19ConformingYesConformingProcedure 19ConformingProcedure 19ConformingSee Problem
Module, SPC Module Final Audit Log for EvidenceConformingSection 1 - Management
Responsibility & Quality PlanningThe Quality Department shall review, address, and
document customer and internal concerns.
Objective EvidenceConformingNonconformingNAProcedure 29Conforming8D and/or other
customer required formats (i.e. 5-Why)ConformingProblem Module issues a tracking
number (i.e RMA)ConformingReview Problem Module for evidenceConformingSection 1 -
Management Responsibility & Quality PlanningThe organization shall have a continual
improvement process.
Objective EvidenceConformingNonconformingNA
• The quality management system shall include a documented process for reprocessing
that shall include authorization from the quality manager or a designated
individual.
• The reprocessing procedure shall describe product characteristics for which
reprocessing is allowed as well as those characteristics for which reprocessing is
not permissible.
• All reprocessing activity shall require a separate rework specific process
control sheet or other identification method, issued by qualified technical
personnel denoting the necessary surface finishing modifications.
• Records shall clearly indicate when and how any material has been reprocessed.
• The rework of material shall comply with the customer’s specifications and/or
requirements.
GuidanceDescribe the procedure for authorizing reprocessing of nonconforming
material.
Does the reprocessing procedure describe product characteristics that allow or not
allow reprocessing?
Did the quality manager or manager’s designee authorize the rework and determine
the reprocessing procedure?
How do you identify that material has been reprocessed?
Do the records clearly indicate when and how any material has been reprocessed
including the quality manager’s authorization
of release?
Provide evidence that the rework complies with your customer's specifications
and/or requirements.
Comments:
1.13The quality management system shall include a process for documenting,
reviewing, and addressing customer concerns and any other concerns internal to the
organization.
GuidanceDescribe the procedure for reviewing and addressing external customer and
internal concerns.
Describe the problem solving approach that is used.
Describe the communication process used to respond to the originator.
Provide a recent example of this procedure in use.
Comments:
1.14• The continual improvement process shall be designed to achieve improvements
in quality and productivity.
• Identified actions shall be prioritized and shall include timing (estimated
completion dates).
• The organization shall show evidence of program effectiveness.
Guidance
Procedure 32ConformingReview CIPA Log in Management Review for
evidenceConformingReview CIPA Log in Management Review for
evidenceConformingSection 1 - Management Responsibility & Quality PlanningThere
shall be predefined personnel responsible for management of materials in quarantine
area.
Objective EvidenceConformingNonconformingNAProcedure 29 and Problem
ModuleConformingMatt Morris (Quality Manager) and Dave Houser (Plant
Manager)ConformingReview Problem Module for evidence (Question in Hold
Log)ConformingSection 1 - Management Responsibility & Quality PlanningThere shall
be documented procedures and/or work instructions for all processes and they shall
be available to all of the organization’s personnel.
Objective EvidenceConformingNonconformingNADMFWI112, DMFWI071, DMFWI072, DMFWI073,
DMFWI074,
DMFWI075,DMFWI076, DMFWI077ConformingDMF147ConformingProcedure 29, Procedure
08ConformingProcedure 19ConformingAvailable Electronically at each work
station.ConformingSection 1 - Management Responsibility & Quality PlanningThe
organization and management shall provide employee training.
Describe the continual improvement process used to achieve improvements in quality

and productivity.
Provide a recent example of how actions are identified, prioritized and completion
dates assigned.
Describe how the organization measures the effectiveness.
Comments:
1.15Only the quality manager or designee may authorize the disposition of material
from quarantine status.
GuidanceDefine the process for release of material from quarantine.
List the authorized personnel with job titles.
Review evidence that only these persons are releasing materials from the quarantine
area.
Comments:
1.16• There shall be procedures or work instructions available to personnel
covering their responsibilities.
• These documents shall include instructions for addressing potential emergencies
(such as power failure), equipment start-up, equipment shut-down, product
segregation (See 2.3, 2.8), product inspection, and general
operating procedures.
GuidanceReview the procedure/work instruction for process start-up and shut-down.
Review the procedure/work instruction for process control during operation.
What is the procedure in place to address potential emergencies?
(Such as power outage and/or equipment failure).
Review the procedures for inspection of the product, in process or after
completion.
Verify that these procedures/work instructions are accessible to personnel
performing the job at all times.
Comments:
1.17
Objective EvidenceConformingNonconformingNAProcedure 06ConformingProcedure
06ConformingReview Training Module for evidenceConformingReview Training Module for
evidenceConformingSection 1 - Management Responsibility & Quality PlanningEssential
management and supervisory functions shall be performed by qualified personnel at
all times and a matrix of these essential responsibilities shall be available for
review.
Objective EvidenceConformingNonconformingNAFORM DMF301ConformingFORM
DMF301ConformingDocument ModuleConformingSection 1 - Management Responsibility &
Quality PlanningThere shall be a preventive maintenance program and maintenance
data shall be utilized to form a predictive/preventive maintenance program.
Objective EvidenceConformingNonconformingNAProcedure 23, Maintenace Log, Spart Part
LogConforming
• The organization shall provide employee training for all operations.

• All employees, including backup and temporary employees, shall be trained.
• Documented evidence shall be maintained showing the employees trained and the
evidence shall include an employee assessment.
• Management shall define the qualification requirements for each function, and
ongoing or follow-up training shall also be addressed.
GuidanceReview the process for initial training of all employees, including backup
and temporary.
Review the process for ongoing and/or follow-up training.
Provide a recent copy of the training matrix.
Provide documented evidence that shows how the organization verifies effectiveness
of training.
Comments:
1.18• The organization shall maintain a responsibility matrix identifying all
essential management and supervisory functions and list the qualified personnel who
may perform such functions.
• It shall identify both primary and secondary (backup) personnel for the essential
functions (as defined by the organization).
• This matrix shall be readily available to management at all times.
GuidanceReview and provide an example of the most recent matrix.
Confirm that the matrix includes both primary and secondary persons.
Describe how and where this information is made available.
Comments:
1.19• The organization shall have a documented preventive maintenance program for
essential process equipment (as identified by the organization).
• The program shall be a closed-loop process that tracks maintenance efforts from
request to completion to assessment of effectiveness.
• Equipment operators shall have the opportunity to report problems, and problems
shall also be handled in a closed-loop manner.
• Company data, e.g., downtime, quality rejects, first time-through capability,
recurring maintenance work orders, and operator-reported problems, shall be used to
improve the preventive maintenance program.
• Maintenance data shall be collected and analyzed as part of a preventive
maintenance program.
GuidanceShow evidence that a documented preventive maintenance program exists.
Requests are sent to the Plant Manager who is responsible for
scheduling tasks with the Maintenance Department. Results are
recorded in the Notes section of the Maintenance Log.
ConformingSee notes section within Maintenance Log for evidence (e.g. DSL
controller for Line 2 plating tank)ConformingSee Change Records within Maintenance
Log for EvidenceConformingManagement ReviewConformingSection 1 - Management
Responsibility & Quality PlanningThe organization shall develop a critical spare
part list and the parts must be available to minimize production disruptions.
Objective EvidenceConformingNonconformingNAREC007 in Document
ModuleConformingREC007 in Document ModuleConformingMonthly
ReviewConformingProcedure 23ConformingProcedure 23, Spare Part LogConforming
Describe the process for reporting problems.

Provide a recent example showing that the person reporting the problem received
feedback after the problem was resolved.
Give a recent example of how the program was used to prevent/predict potential
equipment failure.
How is the data being generated reviewed with management to improve the quality
system?
Comments:
1.20• Spare part suppliers, minimum quantity and lead times shall be documented.
GuidanceProvide the critical spare parts list.
Does the critical spare parts list include inventory, lead time and suppliers?
Describe how and when the organization updates the list.
What criteria is used to determine whether critical spare parts are kept at the
facility or sourced off site.
Describe the process used to maintain minimum quantities.
Comments:
Section 2 - Floor and Material Handling ResponsibilityThe organization shall ensure
that customer data entered into the receiving system matches the customer’s
shipping documents.
Objective EvidenceConformingNonconformingNAProcedure 17, Procedure 19ConformingFORM
DMF114 ,FORM DMF135, FORM DMF250ConformingSee Conrol Plan for
EvidenceConformingSection 2 - Floor and Material Handling ResponsibilityIs product
clearly identified and stored throughout the surface finishing process and is lot
traceability and integrity maintained?
Objective EvidenceConformingNonconformingNAProcedure 17, Final Audit
LogConformingParts received, on hold, and finished are stored in locations marked
with signage and will be marked with an identifying tag (DMF114,
DMF135, DMF250) or a hold tag (DMF221)
ConformingSection 2 - Floor and Material Handling ResponsibilityProcedures shall be
adequate to prevent movement of nonconforming product into and out of the
production system.
2.1It is critical that all customer requirements and lot identification be

correctly transferred to internal documents.
• The facility shall ensure that the data entered in the receiving system match the
information on the customer's shipping documents.
• Documented processes and evidence of compliance shall exist, e.g., shop
travelers, work orders, etc.
• Sometimes the material received does not precisely correspond to customer
shipping documents. The facility shall have a detailed procedure in place to
resolve receiving discrepancies.
• The requirements stated above apply to captive, in-house, commercial and all
involved departments.
GuidanceDescribe the receiving process including listing the documentation used.
Describe the process to identify the plating requirements.
Describe the reaction process when material received does not correspond to the
customer’s documents.
Comments:
2.2Procedures are required for part and container identification to avoid incorrect
processing or mixing of lots.
• As received, in-process, and finished product or material shall be properly
segregated, identified, and stored in a dedicated and clearly defined area.
• Out-going lot(s) shall be traceable to the incoming lot(s).
• The discipline of precisely identifying lots and linking all pertinent
information to them enhances the ability to do root cause analysis and continual
improvement.
GuidanceDescribe the method that ensures the parts and lot numbers are correctly
identified and maintained throughout the process.
Verify that received, in-process, and finished product or material is properly
segregated, identified, and stored in a dedicated
and clearly defined area.
Comments:
2.3The control of suspect or nonconforming product is necessary to prevent
inadvertent shipment or contamination of other lots.
• Procedures shall be adequate to prevent movement of nonconforming product into
the production system.
• Procedures shall exist addressing authorized personnel, appropriate disposition,
product identification and tracking of material flow in and out of hold area.
• Nonconforming hold area shall be clearly designated to ensure segregation of such
material.
Objective EvidenceConformingNonconformingNALocated by the door that leads from the
plant to the main office and
identified with a sign.ConformingProcedure 29ConformingReview Problem module for
evidence.ConformingSection 2 - Floor and Material Handling ResponsibilityFor bulk
processing there shall be a procedure to identify trap points throughout the entire
process to reduce risk of unfinished, improperly coated and mixed parts.
Objective EvidenceConformingNonconformingNAProcedure 17ConformingSee signage posted
at each line and in the shipping/receiving area.ConformingSection 2 - Floor and
Material Handling ResponsibilityThe handling, storage and packaging shall be
adequate to ensure product quality is maintained throughout the entire process.
Objective EvidenceConformingNonconformingNALoading/Unloading ConformingCustomer
owned containers are stored in a clean, dry environment.ConformingContainers are
customer ownedN/ADMF147, Customer specified materialsConformingWarehouse at 625 or
924 W. 15th StreetConforming
GuidanceWhere is the nonconforming holding area, and how is it identified?

Describe the procedure to prevent the unauthorized movement of nonconforming
products.
Provide evidence that material movement in and out of this area is documented.
Comments:
2.4• The organization shall have documented procedures to identify and monitor all
trap points for each process/equipment.
• Monitoring of potential trap points shall occur at minimum every part changeover.
• Trap points may include: Plating barrels, part containers, loading and unloading
equipment, spin dryers, transfer belts.
GuidanceDescribe the procedure to identify and monitor all trap points for each
process and/or equipment.
Provide the list of trap points.
Comments:
2.5• Handling, storage, and packaging shall be adequate to ensure product quality.
• Part cleanliness shall be maintained throughout the process.
• All parts shall be stored in a controlled environment.
GuidanceWhich process steps have dedicated in-process containers?
How are containers maintained to preserve part cleanliness?
Describe how the containers are inspected to ensure they are free of foreign
material.
What is used for liner material of customer containers before packing finished
goods for shipment?
(Materials like newspapers, used cardboard and bags should be avoided).
Provide a list of dedicated storage areas that avoid exposure to contamination and
corrosion.
(Storage outdoors, near media blasting and corrosive processes such as acid tanks
should be avoided).
Comments:
Section 2 - Floor and Material Handling ResponsibilityEach process step shall be
documented and traceable.
Objective EvidenceConformingNonconformingNAForm DMF147ConformingUse of automatic
lines that force all steps in the process to be done in
the order specified on the control plan.ConformingN/AN/AN/AN/ASection 2 - Floor and
Material Handling ResponsibilityPart loading shall be specified, documented and
controlled.
Objective EvidenceConformingNonconformingNAForm DMF147ConformingForm DMF147, Form
DMF220ConformingSection 2 - Floor and Material Handling ResponsibilityThere shall
be a procedure for material handling, containment action and product segregation in
the event of an unplanned process interruption.
Objective EvidenceConformingNonconformingNAQuality Manual, Process Flow Maps,
Control Plans, DMF147ConformingPFMEAs, Procedure 19, Procedure 29, DMFWI112,
DMFWI071,
DMFWI072, DMFWI073, DMFWI074, DMFWI075,DMFWI076,
DMFWI077Conforming
2.6How does the operator verify that all process steps have been completed in
specified order and in within specified time limits?
GuidanceDo you have a document (shop travelers, job sheet, etc.) that specifies all
the processes for each part number/part family?
Define the procedure that ensures that all processes have been completed in the
specified order.
Describe how time sensitive processes are completed in the specified time limits
(e.g., hydrogen embrittlement baking).
Provide documentation that this process has been followed.
Comments:
2.7• Loading parameters shall be specified, documented and controlled.
• Examples include: parts per rack, part position and orientation, weight per
barrel or masking.
GuidanceDescribe how the loading parameters are communicated to the operator.
Identify how the loading weight or rack quantity is recorded for each load or rack.
Comments:
2.8Unplanned downtime greatly increases the risk of improper processing.
• Work instructions specifically addressing potential types of unplanned process
interruptions shall be accessible to operators.
• Specific instructions shall address containment/reaction plans for each step of
the process. Where processes are time critical, immediate actions are required.
Examples include process steps exposing parts to: acidic
solutions, current, bake or curing processes.
• Evidence shall exist showing disposition and traceability of affected product.
GuidanceWhat procedure is used to address each step of the process?
Provide all work instructions that address unplanned process interruptions.
Final Audit Log, Problem ModuleConformingSection 2 - Floor and Material Handling
ResponsibilityPlant cleanliness, environment, and working conditions shall be
conducive to ensure product quality.
Objective EvidenceConformingNonconformingNAProcedure 09ConformingProcedure 29,
DMF147ConformingProcedure 29, DMF147ConformingProgram 10000ConformingSection 2 -
Floor and Material Handling ResponsibilityPlant lighting shall be adequate in all
inspection areas.
Objective EvidenceConformingNonconformingNALighting is monitored quarterly as part
of the building maintenance
plan.ConformingNo appearance items per IATF16949 8.6.3N/A
How is the affected product traced, dispositioned and documented?

Comments:
2.9• Plant cleanliness, housekeeping, environmental, and working conditions shall
be adequate to preserve product quality.
• A housekeeping policy shall be clearly defined and executed.
GuidanceProvide a copy of the housekeeping procedure.
Provide a copy of the procedure used to handle dropped or spilled parts.
Describe what is done with loose parts found on the floor of the plant.
Define the process used to review the facility for conditions that are detrimental
to quality processing such as chemical spills
and inadequate ventilation.
Comments:
2.10Lighting in the part and/or process inspection areas must be adequate for the
intended operation.
GuidanceHow do you ensure the lighting in the part and/or process inspection areas,
including loading and unloading areas, is adequate
for the intended operation?
For part inspection, how do you arrange the lighting to avoid spot lighting, glare,
shadows and distracting reflections?
Comments:
Product AuditDMF338 Rev 01 10/21/2019Job Identity:
Customer: Metal Flow
Shop Order Number: 110419-01-65
Part Number: MFG-1644
Part Description: Housing
Material Substrate: Steel
Plating Requirements: Zinc Iron Plating
Specification Number and Revision: N/A (.0002" per Print)
Question
NumberInspection ElementIdentify Relevant Documents & Actual Condition(Provide Data
or Values & Embed or Attach
Documents)
ConformingNonconformingNA4.1Attach evidence that the documentation for the
specific part conforms to the requirements including:
• Advanced quality planning process• FMEA• Process Control PlanPPAP completed on
01/19/2011. Reviewed
DMFL001, FMEA01, ControlPlan01Conforming4.2What customer specifications or
requirements are
used for this part?
• List the specification(s) and revision(s)
None. The print calls out the plating thickness
and corrosion requirements.Conforming4.3Provide evidence of receiving
inspection.DMF250 (110419-01-65)Conforming4.4Provide the job traveler or attach a
copy of this
traveler showing:
• Customer name• Lot number• Weight/quantity• Process instructions• Inspection
requirements
Review DMF250 (Traveler), DMF147 (Work
Instruction) and DMF140 (Final Audit Log) for
evidence.
Conforming4.5If the lot is divided how is the traceability maintained
throughout the process?
Parts ship in the same containers that they
arrived in.
N/A4.6Describe the method used to document each
operation as being completed. Is there a sign-off with
time stamp, bar code or scan, etc., after each
operation?
DMF250Conforming4.7Attach work instructions applicable to this part
indicating proper barrel/basket mesh size or
perforation (hole size), load size, appropriate rack
configuration, appropriate part orientation on rack,
etc.
DMF147Conforming4.8Identify each process table pertaining to this job audit.
Populate the applicable process tables with the actual
process results/conditions at the time this part was
processed (Columns H and I in Process Tables A
through H).
See Process TablesConforming4.9Were appropriate process steps on the job
router/traveler signed off? For electronic systems, a
screen print is acceptable.
DMF250Conforming4.10Were all inspection steps, as documented in the
control plan performed?
ERP Line Checks and SPC ModuleConforming4.11Were steps/operations performed that
were not
documented in the control plan?
NoConforming4.12If additional steps were performed, were they
authorized?
N/A
4.13If the order was certified, did the certification
accurately reflect the process performed?
N/A4.14Was the certification signed by an authorized
individual?
N/A4.15Are the parts and containers free of foreign objects or
contamination?
Zytecs were clean / free of foreign objectsConforming4.16Are packaging requirements
identified? DMF147Conforming4.17Are parts packaged to prevent mixing or damage to
parts (parts packed over height of container)?
Parts were packaged in customer supplied Zytecs
and hooked at the end of each lot to ensure the
appropriate number of pieces went back into
each boxConforming4.18Are storage condition sufficient to maintain part
quality. e.g., parts are stored indoors in a clean, dry
environment.
Parts were stored in warehouse located at 924 W
15th StreetConforming4.19Were the parts properly identified and/or labeled
before shipping?
DMF250. Tag was stamped "Final Audit
Complete, Ready to Ship"
Conforming4.20For the finished part, list each test and inspection
requirement per customer specification.
Each part may have one or more requirements determined by the
plating specification. Parts must meet each requirement.
Inspection ElementInspection RequirementConformingNonconformingNAInsert audit data
below this line. Add additional sections as needed.
Test Description:Plating Thickness4.20.1Test Method:Procedure 19ConformingTest
frequency or quantity:First 6, one per hour, Last 6ConformingTest
Requirement:.00020"ConformingResult:
Attach evidence:
.00028" - .00040"ConformingTest Description:Corrosion Resistance
4.20.2Test Method:ASTM B117ConformingTest frequency or quantity:As
RequiredConformingTest Requirement:6 hrs. no white / 480 hours no
redConformingResult:
Attach evidence:
Report Number K06191Conforming
Customer: Tenneco
Part Number: XM02B921870
Part Description: Exhaust Isolator
Plating Requirements: Zinc Nickel Plating
Specification Number and Revision: PS.152.15A Rev G
Question
Documents)
• Advanced quality planning process• FMEA• Process Control PlanPPAP approved on
requirements are
used for this part?
PS.152.15A Rev GConforming4.3Provide evidence of receiving inspection.DMF250
(110419-02-30)Conforming4.4Provide the job traveler or attach a copy of this
traveler showing:
requirements
evidence.
arrived in.
operation?
etc.
through H).
were not
authorized?
N/A
individual?
contamination?
Cardboard boxes were clean / free of foreign
objectsConforming4.16Are packaging requirements identified? DMF147Conforming4.17Are
parts packaged to prevent mixing or damage to
Parts were packaged in customer supplied boxes
appropriate number of pieces go back in each
boxConforming4.18Are storage condition sufficient to maintain part
environment.
before shipping?
Requirement:.00024" - .00079"ConformingResult:
Attach evidence:
.00038" - .00065"ConformingTest Description:Nickel Percent
4.20.2Test Method:Procedure 19ConformingTest frequency or quantity:First 6, one per
hour, Last 6ConformingTest Requirement:10-17%ConformingResult:
Attach evidence:
12.1% - 13.7%ConformingTest Description:Corrosion Resistance
RequiredConformingTest Requirement:720 hours no redConformingResult:
Attach evidence:
Customer: Cooper / Conitech
Part Number: 2569651
Part Description: Upper Isolator Sub Assy
Material Substrate: Zinc Nickel
Plating Requirements: .00031' - .00055" | 12% - 17% Nickel
Specification Number and Revision: WSS-M21P51-A2
Question
Documents)
• Advanced quality planning process• FMEA• Process Control PlanPPAP approved on
06/15/2017. ReviewedDMFL002 OSP, FMEA02 OSP, ControlPlan02
OSP
Conforming4.2What customer specifications or requirements are
used for this part?
WSS-M21P51-A2 (Rev02 2019-03-22)
Conforming4.3Provide evidence of receiving inspection.DMF250 0(12820-02-
86)Conforming4.4Provide the job traveler or attach a copy of this
traveler showing:
requirements
Review DMF250 (Traveler), DMF147 (WorkInstruction) and DMF140 (Final Audit Log)
forevidence.
Tags are being discarded during repack per
customer instructions.
Conforming4.6Describe the method used to document each
operation?
etc.
DMF147, DMFWI128Conforming4.8Identify each process table pertaining to this job
audit.
through H).
Reference Line 2 Process TableConforming4.9Were appropriate process steps on the
job
ERP Line Checks, SPC Module, DMFWI128Conforming4.11Were steps/operations performed
that were not
authorized?
N/A
accurately reflect the process performed?N/A4.14Was the certification signed by an
authorized
individual?N/A4.15Are the parts and containers free of foreign objects or
contamination?
Zytecs were clean / free of foreign objectsConforming4.16Are packaging requirements
identified? DMF147, DMFWI128Conforming4.17Are parts packaged to prevent mixing or
damage to
Parts were layer packed in customer supplied
zytecsConforming4.18Are storage condition sufficient to maintain part
environment.
before shipping?
Per communication with Cooper, the
established/approved process does not
accomidate thisConforming4.20For the finished part, list each test and inspection
Test Description: Plating Thickness4.20.1Test Method: Procedure 19ConformingTest
frequency or quantity: First 6, one per hour, Last 6ConformingTest Requirement: .
00031" - .00055"ConformingResult:
Attach evidence:
.00039"ConformingTest Description: Nickel Percent4.20.2Test Method: Procedure
19Procedure 19ConformingTest frequency or quantity: First 6, one per hour, Last
6ConformingTest Requirement: 12-17% ConformingResult:
Attach evidence:
13.11%ConformingTest Description:Corrosion Resistance4.20.3Test Method:WSS-M1P87-
A2ConformingTest frequency or quantity:As RequiredConformingTest Requirement:240 H
no White | 960 Hours no RedConformingResult:
Attach evidence:
Report Number A31201Conforming
Customer: ITW
Part Number: DA030-05
Part Description: Housing
Plating Requirements: Zinc Plating
Specification Number and Revision: N/A (.0003" - .0005" per Print)
Question
Documents)
requirements are
used for this part?
None. The print calls out the plating thickness
and corrosion requirementsN/A4.3Provide evidence of receiving inspection.DMF250
(Lot 102119-03-49)Conforming4.4Provide the job traveler or attach a copy of this
traveler showing:
requirements
evidence.
arrived in.
operation?
etc.
through H).
were not
authorized?
N/A
individual?
contamination?
Totes were clean / free of foreign objectsConforming4.16Are packaging requirements
identified? DMF147Conforming4.17Are parts packaged to prevent mixing or damage to
Parts were packaged in customer supplied
containers and scale counted according to the
quantity listed on the customer labelConforming4.18Are storage condition sufficient
to maintain part
environment.
before shipping?
Requirement:.00030" - .00050"ConformingResult:
Attach evidence:
.00031" - .00039"ConformingTest Description:Adhesion Test
4.20.2Test Method:DMFWI090ConformingTest frequency or quantity:1 per
ShipmentConformingTest Requirement:No adhesion lossConformingResult:
Attach evidence:
PassConformingTest Description:Corrosion Resistance
RequiredConformingTest Requirement:6 hrs. no white / 96 hours no
redConformingResult:
Attach evidence:
Report Number J21191Conforming
Customer: Vibracoustic
Part Number: U-31096-303
Part Description: Outer Metal
Plating Requirements: Zinc Nickel Plating
Specification Number and Revision: TES 1207 Rev REL
Question
Documents)
requirements are
used for this part?
TES 1207 Rev RELConforming4.3Provide evidence of receiving inspection.DMF250
(110419-04-75)Conforming4.4Provide the job traveler or attach a copy of this
traveler showing:
requirements
evidence.
arrived in.
operation?
etc.
through H).
were not
authorized?
N/A
individual?
contamination?
Plastic totes were clean / free of foreign objectsConforming4.16Are packaging
requirements identified? DMF147Conforming4.17Are parts packaged to prevent mixing
or damage to
Parts were packaged in customer supplied totes
appropriate number of pieces went into each
boxConforming4.18Are storage condition sufficient to maintain part
environment.
before shipping?
Requirement:.00023"ConformingResult:
Attach evidence:
.00030" - .00068"ConformingTest Description:Nickel Percent
4.20.2Test Method:Procedure 19ConformingTest frequency or quantity:First 6, one per
hour, Last 6ConformingTest Requirement:10-15%ConformingResult:
Attach evidence:
12.5% - 14%ConformingTest Description:Adhesion Test
4.20.3Test Method:DMFWI123ConformingTest frequency or quantity:First 3, one per
hour, Last 3ConformingTest Requirement:No adhesion lossConformingResult:
Attach evidence:
PassConformingTest Description:Corrosion Resistance
RequiredConformingTest Requirement:720 hours no redConformingResult:
Attach evidence:
CQI-11
PROCESS TABLE A - Zinc & Zinc Alloy PlatingAll requirements given below are
subordinate to applicable customer/OEM specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater
frequencies, etc. When performing the job audit, the auditor shall verify plater is
conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual
conditions. To justify reduced monitoring frequencies, a minimum of 30 consecutive
measurements (data points) at stated frequencies must be documented.
If any data points at reduced monitoring frequencies are outside of control limits,
then revert back to the frequencies stated under the minimum requirements.
Columns H and I are used for the Job Audit (Section 4).
Regularly scheduled measurements (e.g., temperature, concentrations, pH) are to be
entered in the appropriate row.
For sections that are not applicable mark NA in the Comments column.
Instruction for creating the table with the form builder:
Using the Populate Forms list to the right, select the box that represents the
first step of the process flow.
Then select the Populate Forms banner and that section of the process table will be
added below.
For each additional step of the process flow, continue adding sections to the form
by selecting the applicable step from the list to the right, followed by selecting
the Populate Forms banner.
Rinses between process steps are to be included.
If using multiple counter flowed rinses only insert one Rinse section, document
only the condition of the last rinse tank in the series.
Process Line Identification: Line 1Type of Line: Rack
Category/Process StepsObservation/
CommentsType of ControlMonitoring FrequencyJob Audit MeasurementsMinimum
RequirementActual ConditionMinimum RequirementActual
ConditionConformingNonconformingNARangeActual
Measurements
supporting time of
Job AuditAlkaline CleaningType: SoakSize, volume: ConfidentialChemical supplier:
ConfidentialTemperature (Thermocouple)
AutomaticMax SAT difference allowed
+/- 5oC (10oF).
AutomaticContinuous monitoring by controller. Manually verify daily.1/8 hours
workedConformingSee Control Plan169ConcentrationManualManualOnce per day.1/24 hours
workedConformingSee Control Plan12TimeAutomaticAutomaticAfter any program
changes.N/AN/AN/A4 Min.
Agitation (if applicable)AutomaticAutomaticOnce every 8 hours.1/8 hours
workedConformingSee Control PlanYesSolution Level
- Parts, heaters, and transducers are completely submerged.Automatic or
ManualManualContinuous monitoring by controller. Manually verify daily for
automatic controls, every 8 hours for systems without
controllers.
1/8 hours workedConformingSee Control PlanYesImpurity Content CheckPer chemical
supplier recommendation such as:
- acid split (oil contamination)
- alkalinity ratioManualNot
Recommended by
Chemical SupplierOnce per week*N/AN/AN/A1.5 : 1Tank and solution maintenance
schedule documented and
followed.ManualManualPer preventive maintenance program.1/
monthConformingN/ACompleteAlkaline CleaningType - Electro (cathodic)
Size, volume: ConfidentialChemical supplier: Confidential
ITEM #
1.0A1.1A1.2A1.3A1.4A1.5A1.6A1.72.0

Temperature (Thermocouple)
+/- 5oC (10oF).
workedConformingSee Control Plan10TimeAutomaticAutomaticAfter any program
workedConformingSee Control PlanYesAmperage or Voltage Control (if
applicable)AutomaticAutomaticOnce every 8 hours*.1/8 hours workedConformingSee
Control Plan3.8Solution Level
controllers.
- alkalinity ratioManualN/AOnce per week*N/AN/AN/A1.4 : 1Tank and solution
maintenance schedule documented and
monthConformingN/ACompleteRinse (This section is to be repeated as necessary to
document all individual rinse steps in the entire
Rinse Type - Identify in comment sectione.g., Flowing, Counter Flowing, Spray,
Stagnant, Drag-in/out,
etc.
NANANANACounter FlowingWater Type- Identify in comment section
e.g., Municipal, Deionized (DI),Reverse Osmosis (RO), etc.
NANANANAMunicipalAgitation type - Identify in comment section (if applicable)
e.g., Mechanical (Describe), Air, Ultrasonic, etc.NANANANAAirSolution Level
controllers.
1/8 hours workedConformingSee Control PlanYesRinse Quality - Identify in comment
sectione.g., pH, Impurity Check, ConductivityManualManualOnce every 8 hours.*1/8
hours workedConformingSee Control PlanYesFlow rate (if applicable)ManualManualOnce
every 8 hours.1/8 hours workedConformingSee Control PlanYesVerify position of
incoming water feed is near the bottom (if
immersion tank).ManualManualPer preventive maintenance program.1/
monthConformingN/ACompleteTank and solution maintenance schedule documented and
monthConformingN/ACompleteAcid PicklingType: HCLSize, volume: ConfidentialChemical
supplier: ConfidentialConcentrationManualManualOnce every 8 hours*2/24 hours
worked.
Conforming. Data
points show that
reduced
frequency is able
to maintain
process control.
See Control Plan41.6Metallic impurity concentration. Obtain metallic impurity
limits
from chemical supplier with required corrective actions. ManualManualOnce per
month.1/ monthConformingSee Control Plan4.325 | 1169Time (Less than 10 Minutes or
Customer Specific)AutomaticAutomaticAfter any program changes.N/AN/AN/A4 Min.
Solution LevelManualManualOnce every 8 hours.1/8 hours workedConformingSee Control
PlanYesTank and solution maintenance schedule documented and
etc.
NANANANAFlowingWater Type- Identify in comment section
controllers.
hours workedConformingSee Control PlanYes
A2.1A2.2A2.3A2.4A2.5A2.6A2.7A2.83.0A3.1A3.2A3.3A3.4A3.5A3.6A3.7A3.84.0A4.1A4.2A4.3A
4.4A4.55.0A5.1A5.2A5.3A5.4A5.5
CQI-11
Flow rate (if applicable)ManualManualOnce every 8 hours.1/8 hours
workedConformingSee Control PlanYesVerify position of incoming water feed is near
the bottom (if
immersion tank).ManualManual1/Month1/ monthConformingN/ACompleteTank and solution
etc.
controllers.
immersion tank).ManualManual1/Month1/ monthConformingN/ACompleteTank and solution
monthConformingN/ACompleteAlkaline Plating BathType: Zinc-IronSize, volume:
ConfidentialChemical supplier: ConfidentialTemperature (Thermocouple)
+/- 3oC (5oF).
workedConformingSee Control Plan83Time Automatic or ManualAutomaticAutomatic -
After any program changes. Manual - every load.*N/AN/AN/A19 MinSolution Level
controllers.
1/8 hours workedConformingSee Control PlanYesCurrent/VoltageAutomatic or
ManualManualOnce every 8 hours.1/8 hours workedConformingSee Control Plan5.1Plating
Test Cell (Hull Cell)ManualManualOnce per day.1/24 hours workedConformingSee
Control Plan1.7Zinc Generator Tank (if applicable)
-Caustic Concentration-Zinc ConcentrationAutomatic or ManualManualOnce every 8
hours.2/24 hours workedConforming. Data
points show that
reduced
frequency is able
to maintain
process control.
See Control Plan6.625Caustic ConcentrationManualManualOnce per day.1/24 hours
workedConformingSee Control Plan17.9Zinc ConcentrationManualManualOnce per day.2/24
hours workedConformingSee Control Plan1.8Alloying Element Concentration
(e.g., Fe, Ni, Co; if applicable)ManualManualOnce per day.1/24 hours
workedConformingSee Control Plan97Complexor Concentration (for alloy
baths)ManualN/AOnce per month by Supplier.1/ monthConformingSee Letter from
SupplierSee Letter from
SupplierMetallic impurity concentration. Obtain metallic impurity limits
month.1/ monthConformingSee Control Plan0 | 0 | 0 | 0 | 0Carbonate (CO3)
concentrationManualManualOnce per month (Twice per month for alloy plating).2/
monthConformingSee Control Plan9.7Proprietary chemical additives concentration
(e.g., carrier, brightener) ManualN/AOnce per month by Supplier. 1/
monthConformingSee Letter from
SupplierChemical feedersAutomatic AutomaticOnce per week.1/24 hours
workedConformingSee Control Plan52 | 75 | 39Agitation (Rack only - others
optional)ContinuousContinuousOnce every 8 hours.1/8 hours workedConformingSee
Control PlanYesFiltration PressureContinuousN/AOnce every 8 hours.N/AN/AN/AN/A
A5.6A5.7A5.86.0A6.1A6.2A6.3A6.4A6.5A6.6A6.7A6.87.0A7.1A7.2A7.3A7.4A7.5A7.6A7.7A7.8A
7.9A7.10A7.11A7.12A7.13A7.14A7.15A7.16
CQI-11
Fallen part removalManualManualRack: Once every 24 hours.
Barrel: Once per week and after any lost load.1/ weekConformingN/AThe part removal
process may cause
customer rejections
and should only be
done when the line
is not in use.
Tank and solution maintenance schedule documented and
etc.
controllers.
monthConformingN/ACompleteAcid Activation (i.e., nitric, sulfuric, etc.)
pH/concentrationManualAutomaticOnce every 8 hours.1/1 hours workedConformingSee
Control Plan2.2Time Automatic*AutomaticAfter any program changes.N/AN/AN/A1 Min.
Fallen part removalManualManualOnce every 24 hours for rack line.1/24 hours
workedConformingSee Control PlanYesTank and solution maintenance schedule
documented and
etc.
NANANANASprayWater Type- Identify in comment section
e.g., Mechanical (Describe), Air, Ultrasonic, etc.NANANANANARinse Quality -
Identify in comment sectione.g., pH, Impurity Check, ConductivityManualManualOnce
every 8 hours.*N/AN/AN/AN/AFlow rate (if applicable)ManualN/AOnce every 8
hours.N/AN/AN/AN/ASpray nozzle condition (if applicable)ManualManualOnce every 8
hours.1/8 hours workedConformingSee Control PlanYesTank and solution maintenance
monthConformingN/ACompletePassivatesType: Thick Film TrivalentSize, volume:
ConfidentialChemical supplier: ConfidentialConcentrationAutomatic or Manual
Prior to production start-up.
If automatic control, once per day.
If manual, once every 8 hours.
1/24 hours workedConformingSee Control Plan14.7Temperature (Thermocouple)
+/- 1oC (2oF).
After any program changes.
Manual - every load.*N/AN/AN/A1 Min.
Solution Level
controllers.
1/8 hours workedConformingSee Control PlanYes
A7.17A7.188.0A8.1A8.2A8.3A8.4A8.5A8.6A8.7A8.89.0A9.1A9.2A9.3A9.410.0A10.1A10.2A10.3
A10.4A10.5A10.6A10.711.0A11.1A11.2A11.3A11.4
CQI-11
pHAutomatic*AutomaticPrior to production start-up.
1/1 Hours workedConformingSee Control Plan1.98AgitationAutomaticAutomaticOnce every
8 hours.1/8 hours workedConformingSee Control PlanYesMetallic Impurity level(s)
(e.g., Fe, Zn)ManualManualOnce per week.1/ weekConformingSee Control Plan14 (Fe) |
1632 (Zn)
documented and
etc.
controllers.
etc.
controllers.
monthConformingN/ACompleteSupplemental Treatments - Topcoats, Sealants and Friction
ModifiersType: SealerSize, volume: ConfidentialChemical supplier:
ConfidentialConcentrationManualAutomaticPrior to production start-up.
1/24 hours workedConformingSee Control Plan34Temperature (Thermocouple) (if
applicable)
+/- 1oC (2oF).
workedConformingSee Control Plan72pH (if applicable)Automatic or ManualManualPrior
to production start-up.
1/24 hours workedConforming. Data
points show that
reduced
frequency is able
to maintain
process control.
See Control Plan8.6Time Automatic*AutomaticAfter any program changes if
automatic.N/AN/AN/A1 Min.
A11.5A11.6A11.7A11.8A11.912.0A12.1A12.2A12.3A12.4A12.5A12.6A12.7A12.813.0A13.1A13.2
A13.3A13.4A13.5A13.6A13.7A13.814.0A14.1A14.2
A14.3A14.4
CQI-11
Solution Level
controllers.
1/8 hours workedConformingSee Control PlanYesFiltration Pressure (if
applicable)AutomaticOnce every 8 hours.N/AN/AN/AN/ATank and solution maintenance
monthConformingN/ACompleteDryingDrying TimeAutomaticAutomaticPer Process Sheet and
TDS.N/AN/AN/A7 Min.
Drying Temperature (Thermocouple)
+/- 5oC (10oF).
AutomaticPer Process Sheet and TDS.N/AN/ASee Control Plan134Verify operation of
blowers and/or rotation of dryer.ManualManualOnce per 8 hours.1/8 hours
workedConformingSee Control PlanYesThere is a procedure to ensure dryness of
parts.ManualManualEvery container and rack.Every container
and rack.ConformingPer customer
requirementsN/A
A14.5A14.6A14.715.0A15.1A15.2A15.3A15.4
CQI-11
added below.
Measurements
supporting time of
+/- 5oC (10oF).
workedConformingSee Control Plan9.3TimeAutomaticAutomaticAfter any program
controllers.
Size, volume: ConfidentialChemical supplier: ConfidentialTemperature (Thermocouple)
+/- 5oC (10oF).
workedConformingSee Control PlanYes
ITEM #
1.0A1.1A1.2A1.3A1.4A1.5A1.6A1.72.0A2.1A2.2A2.3A2.4
Amperage or Voltage Control (if applicable)AutomaticAutomaticOnce every 8
hours*.1/8 hours workedConformingSee Control Plan3.8Solution Level
controllers.
etc.
controllers.
hours workedConformingSee Control PlanYesFlow rate (if applicable)ManualN/AOnce
every 8 hours.1/8 hours workedConformingSee Control PlanVerify position of incoming
water feed is near the bottom (if
etc.
controllers.
worked.
Conforming. Data
points show that
reduced
frequency is able
to maintain
process control.
limits
month.1/ monthConformingSee Control Plan2.2 | 2216 | 96 | 13
| 2539Time (Less than 10 Minutes or Customer Specific)AutomaticAutomaticAfter any
program changes.N/AN/AN/A5 Min.
etc.
e.g., Mechanical (Describe), Air, Ultrasonic, etc.NANANANAAir
A2.5A2.6A2.7A2.83.0A3.1A3.2A3.3A3.4A3.5A3.6A3.7A3.84.0A4.1A4.2A4.3A4.4A4.5A4.6A4.7A
4.85.0A5.1A5.2A5.3A5.4A5.56.0A6.1A6.2A6.3
Solution Level
controllers.
etc.
controllers.
monthConformingN/ACompleteAlkaline Plating BathType: Zinc-NickelSize, volume:
+/- 3oC (5oF).
After any program changes. Manual - every load.*N/AN/AN/A27 Min.
Solution Level
controllers.
ManualManualOnce every 8 hours.1/8 hours workedConformingSee Control Plan6Plating
points show that
reduced
frequency is able
to maintain
process control.
month.1/ monthConformingSee Control Plan186.5 | .33 | 0 | 0 | 0Carbonate (CO3)
workedConformingSee Control Plan255 | 52 | 250Agitation (Rack only - others
Control PlanYesFiltration PressureContinuousN/AOnce every 8 hours.N/AN/AN/AN/A
A6.4A6.5A6.6A6.7A6.87.0A7.1A7.2A7.3A7.4A7.5A7.6A7.7A7.88.0A8.1A8.2A8.3A8.4A8.5A8.6A
8.7A8.8A8.9A8.10A8.11A8.12A8.13A8.14A8.15A8.16
Fallen part removalManualManualRack: Once every 24 hours.
process may cause
customer rejections
and should only be
done when the line
is not in use.
followed.ManualPer preventive maintenance program.1/
etc.
NANANANAStagnantWater Type- Identify in comment section
controllers.
etc.
NANANANAStagnantWater Type- Identify in comment section
controllers.
monthConformingN/ACompleteAcid Activation (i.e., nitric, sulfuric, etc.)
Control Plan6.2Time Automatic*AutomaticAfter any program changes.N/AN/AN/A1 Mon.
documented and
ConfidentialChemical supplier: ConfidentialConcentrationAutomatic or
ManualAutomaticPrior to production start-up.
1/24 hours workedConformingSee Control Plan13.7Temperature (Thermocouple)
+/- 1oC (2oF).
Manual - every load.*N/AN/AN/A1 Min.
Solution Level
controllers.
1/8 hours workedConformingSee Control PlanYespHAutomatic*AutomaticPrior to
production start-up.
1/1 Hours workedConformingSee Control Plan2.2
A8.17A8.189.0A9.1A9.2A9.3A9.4A9.5A9.6A9.7A9.810.0A10.1A10.2A10.3A10.4A10.5A10.6A10.
7A10.811.0A11.1A11.2A11.3A11.412.0A12.1A12.2
A12.3A12.4A12.5
AgitationAutomaticAutomaticOnce every 8 hours.1/8 hours workedConformingSee Control
PlanYesMetallic Impurity level(s) (e.g., Fe, Zn)ManualManualOnce per week.Once per
weekConformingSee Control Plan170 (Fe) | 9759 (Zn)
documented and
etc.
controllers.
ConfidentialConcentrationManualManualPrior to production start-up.
1/24 hours workedConforming.
Dumped and
replaced every
day.
66Temperature (Thermocouple) (if applicable)
+/- 1oC (2oF).
workedConformingSee Control Plan121pH (if applicable)Automatic or ManualManualPrior
to production start-up.
points show that
reduced
frequency is able
to maintain
process control.
automatic.N/AN/AN/A1 Min.
Solution Level
controllers.
applicable)AutomaticN/AOnce every 8 hours.N/AN/AN/AN/ATank and solution maintenance
TDS.N/AN/AN/A6 Min.
+/- 5oC (10oF).
requirementsN/A
A12.6A12.7A12.8A12.913.0A13.1A13.2A13.3A13.4A13.5A13.6A13.7A13.814.0A14.1A14.2A14.3
A14.4A14.5A14.6A14.715.0A15.1A15.2A15.3A15.4
added below.
Measurements
supporting time of
+/- 5oC (10oF).
controllers.
monthConformingN/AComplete
Alkaline CleaningType - Electro (cathodic)
+/- 5oC (10oF).
changes.N/AN/AN/A4 MinutesAgitation (if applicable)AutomaticAutomaticOnce every 8
hours.1/8 hours workedConformingSee Control PlanYesAmperage or Voltage Control (if
Control Plan4.8
ITEM #
1.0A1.1A1.2A1.3A1.4A1.5A1.6A1.72.0A2.1A2.2A2.3A2.4A2.5
Solution Level
controllers.
Rinse (This section is to be repeated as necessary to document all individual rinse
steps in the entire
etc.
controllers.
sectione.g., pH, Impurity Check, ConductivityManualManualOnce every 8
hours.*ConformingSee Control Plan681
Flow rate (if applicable)ManualN/AOnce every 8 hours.1/8 hours workedConformingSee
Control PlanYes
Verify position of incoming water feed is near the bottom (if
steps in the entire
etc.
controllers.
hours.*ConformingSee Control Plan662
Control PlanYes
Acid PicklingType: HCLSize, volume: ConfidentialChemical supplier:
ConfidentialConcentrationManualManualOnce every 8 hours*2/24 hours
worked.
Conforming. Data
points show that
reduced frequency
is able to maintain
process control.
See Control Plan40%
Metallic impurity concentration. Obtain metallic impurity limits
month.1/ monthConformingSee Control Plan2.225 | 531Time (Less than 10 Minutes or
Customer Specific)AutomaticAutomaticAfter any program changes.N/AN/AN/A3
MinutesSolution LevelManualManualOnce every 8 hours.1/8 hours workedConformingSee
Control PlanYesTank and solution maintenance schedule documented and
steps in the entire
etc.
controllers.
1/8 hours workedConformingSee Control PlanYes
A2.6A2.7A2.83.0A3.1A3.2A3.3A3.4A3.5A3.6A3.7A3.84.0A4.1A4.2A4.3A4.4A4.5A4.6A4.7A4.85
.0A5.1A5.2A5.3A5.4A5.56.0A6.1A6.2A6.3A6.4
Rinse Quality - Identify in comment sectione.g., pH, Impurity Check,
ConductivityManualManualOnce every 8 hours.*1/8 hours workedConformingSee Control
Plan75650
Control PlanYes
immersion tank).ManualManual1/Month1/MonthConformingN/ACompleteTank and solution
steps in the entire
etc.
controllers.
hours workedConformingSee Control Plan988
Control PlanYes
Alkaline Plating BathType: ZincSize, volume: ConfidentialChemical supplier:
+/- 3oC (5oF).
After any program changes. Manual - every
load.*N/AN/AN/A15 MinutesSolution Level
controllers.
ManualManualOnce every 8 hours.1/8 hours workedConformingSee Control Plan6.7Plating
points show that
reduced frequency
is able to maintain
process control.
See Control Plan2.1
Caustic ConcentrationManualManualOnce per day.1/24 hours workedConformingSee
Control Plan18.2Zinc ConcentrationManualManualOnce per day.2/24 hours
workedConformingSee Control Plan1.7Metallic impurity concentration. Obtain metallic
impurity limits
month.Conforming0 | 0 | 0 | 0 | 0
Carbonate (CO3) concentrationManualManualOnce per month (Twice per month for alloy
plating).1/ monthConformingSee Control Plan7.2Proprietary chemical additives
concentration
(e.g., carrier, brightener) ManualManualOnce per month by Supplier. 1/
monthConformingN/ASee Letter from
workedConformingSee Control Plan75Agitation (Rack only - others
Control PlanYesFiltration PressureContinuousN/AOnce every 8
hours.N/AN/AN/AN/AFallen part removalManualManualRack: Once every 24 hours.
process may cause
customer rejections
and should only be
done when the line
is not in use.
steps in the entire
A6.5A6.6A6.7A6.87.0A7.1A7.2A7.3A7.4A7.5A7.6A7.7A7.88.0A8.1A8.2A8.3A8.4A8.5A8.6A8.7A
8.8A8.9A8.10A8.11A8.12A8.13A8.14A8.15A8.169.0
etc.
controllers.
hours.*ConformingPENDING
Control PlanYes
immersion tank).ManualManualPer preventive maintenance
program.1/MonthConformingN/ACompleteTank and solution maintenance schedule
documented and
steps in the entire
etc.
controllers.
Control PlanYesVerify position of incoming water feed is near the bottom (if
program.1/MonthConformingN/ACompleteTank and solution maintenance schedule
documented and
Acid Activation (i.e., nitric, sulfuric, etc.)
Control Plan1.84Time Automatic*AutomaticAfter any program changes.N/AN/AN/A1
MinuteFallen part removalManualManualOnce every 24 hours for rack line.1/24 hours
PassivatesType: Thin Film AND Thick Film TrivalentSize, volume:
1/24 hours workedConformingSee Control Plan7.3
Temperature (Thermocouple) AutomaticContinuous monitoring by controller. Manually
verify daily.1/8 hours workedConformingSee Control Plan82.3Time Automatic or
ManualAutomaticAutomatic - After any program changes.
Manual - every load.*N/AN/AN/A1 MinuteSolution Level
controllers.
1/1 Hours workedConformingSee Control Plan1.96AgitationAutomaticAutomaticOnce every
8 hours.1/8 hours workedConformingSee Control PlanYesMetallic Impurity level(s)
(e.g., Fe, Zn)ManualManualOnce per week.1/ week workedConformingSee Control
Plan45(Fe) | 7033(Zn)
steps in the entire
etc.
e.g., Municipal, Deionized (DI),Reverse Osmosis (RO), etc. NANANANAMunicipal
A9.1A9.2A9.3A9.4A9.5A9.6A9.7A9.810.0A10.1A10.2A10.3A10.4A10.5A10.6A10.7A10.811.0A11
.1A11.2A11.3A11.412.0A12.1A12.2A12.3A12.4A12.5A12.6A12.7A12.8A12.913.0A13.1A13.2
Agitation type - Identify in comment section (if applicable)
controllers.
Flow rate (if applicable)ManualN/AOnce every 8 hours.N/AN/ASee Control PlanYes
program.ConformingN/AN/ACompleteTank and solution maintenance schedule documented
and
steps in the entire
etc.
controllers.
Flow rate (if applicable)ManualN/AOnce every 8 hours.N/AN/ASee Control PlanYes
program.ConformingN/AN/ACompleteTank and solution maintenance schedule documented
and
DryingDrying TimeAutomaticAutomaticPer Process Sheet and TDS.N/AN/AN/A6 MinDrying
Temperature (Thermocouple)
+/- 5oC (10oF).
requirementsN/A
A13.3A13.4A13.5A13.6A13.7A13.814.0A14.1A14.2A14.3A14.4A14.5A14.6A14.7A14.815.0A15.1
A15.2A15.3A15.4
added below.
Measurements
supporting time of
+/- 5oC (10oF).
controllers.
+/- 5oC (10oF).
workedConformingSee Control Plan9
ITEM #
1.0A1.1A1.2A1.3A1.4A1.5A1.6A1.72.0A2.1A2.2
TimeAutomaticAutomaticAfter any program changes.N/AN/AN/A4 Min.
workedConformingSee Control PlanYesAmperage or Voltage Control (if
Control Plan3.8Solution Level
controllers.
etc.
controllers.
worked.
Conforming. Data
points show that
reduced frequency
is able to maintain
process control.
limits
month.1/ monthConformingSee Control Plan4.325 | 2,039Time (Less than 10 Minutes or
Customer Specific)AutomaticAutomaticAfter any program changes.N/AN/AN/A4 Min.
etc.
controllers.
etc.
NANANANAFlowing
A2.3A2.4A2.5A2.6A2.7A2.83.0A3.1A3.2A3.3A3.4A3.5A3.6A3.7A3.84.0A4.1A4.2A4.3A4.4A4.55
.0A5.1A5.2A5.3A5.4A5.5A5.6A5.7A5.86.0A6.1
Water Type- Identify in comment section
controllers.
monthConformingN/ACompleteAlkaline Plating BathType: Zinc-NickelSize, volume:
+/- 3oC (5oF).
After any program changes. Manual - every load.*N/AN/AN/A26 MinSolution Level
ManualContinuous monitoring by controller. Manually verify daily for
controllers.
ManualManualOnce every 8 hours.1/8 hours workedConformingSee Control Plan5Plating
-Caustic Concentration-Zinc ConcentrationAutomatic or ManualOnce every 8 hours.2/24
hours workedConforming. Data
points show that
reduced frequency
is able to maintain
process control.
month.1/ monthConformingSee Control Plan3.95 | 0 | 0 | 0 | 0 | 0Carbonate (CO3)
workedConformingSee Control Plan240, 49, 245Agitation (Rack only - others
Control PlanYesFiltration PressureContinuousN/AOnce every 8
hours.N/AN/AN/AN/AFallen part removalManualManualRack: Once every 24 hours.
process may cause
customer rejections
and should only be
done when the line
is not in use.
etc.
NANANANACounter Flowing SprayWater Type- Identify in comment section
e.g., Mechanical (Describe), Air, Ultrasonic, etc.NANANANAAir
A6.2A6.3A6.4A6.5A6.6A6.7A6.87.0A7.1A7.2A7.3A7.4A7.5A7.6A7.7A7.8A7.9A7.10A7.11A7.12A
7.13A7.14A7.15A7.16A7.17A7.188.0A8.1A8.2A8.3
Solution Level
controllers.
every 8 hours.1/8 hours workedConformingSee Control PlanYesSpray nozzle condition
(if applicable)ManualManualOnce every 8 hours.1/8 hours workedConformingSee Control
PlanYesVerify position of incoming water feed is near the bottom (if
1/24 hours workedConformingSee Control Plan6Temperature (Thermocouple)
+/- 1oC (2oF).
Manual - every load.*N/AN/AN/A1 MinSolution Level
controllers.
1/1 Hour workedConformingSee Control Plan4.3AgitationAutomaticAutomaticOnce every 8
hours.1/8 hours workedConformingSee Control PlanYesMetallic Impurity level(s)
(e.g., Fe, Zn)ManualManualOnce per week.1/ week workedConformingSee Control Plan3
(Fe) | 1422 (Zn)
workedConformingSee Control PlanYESTank and solution maintenance schedule
documented and
etc.
controllers.
ConfidentialConcentrationManualManualPrior to production start-up.
1/24 hours workedConforming.
Dumped and
replaced every
day.
66Temperature (Thermocouple) (if applicable)
+/- 1oC (2oF).
workedConformingSee Control Plan121
A8.4A8.5A8.6A8.7A8.8A8.99.0A9.1A9.2A9.3A9.4A9.5A9.6A9.7A9.8A9.910.0A10.1A10.2A10.3A
10.4A10.5A10.6A10.7A10.811.0A11.1A11.2
pH (if applicable)Automatic or ManualManualPrior to production start-up.
points show that
reduced frequency
is able to maintain
process control.
automatic.N/AN/AN/A1 MinSolution Level
controllers.
applicable)AutomaticN/AOnce every 8 hours.N/AN/AN/AN/ATank and solution maintenance
TDS.N/AN/AN/A6 Min.
+/- 5oC (10oF).
requirementsN/A
A11.3A11.4A11.5A11.6A11.712.0A12.1A12.2A12.3A12.4
PROCESS TABLE I - Process Control and Testing Equipment Verification and
CalibrationAll requirements given below are subordinate to applicable customer/OEM
specific requirements.
frequencies, etc. The auditor shall verify plater is conforming to customer
requirements.
measurements (data
points) at stated frequencies must be documented. If any data points at reduced
monitoring frequencies are outside of control limits, then revert back to the
frequencies stated under the
minimum requirements.
ITEM #EQUIPMENT TYPEVerification FrequencyConformingNonconformingNACalibration /

Certification
FrequencyConformingNonconformingNAObservation /
Comments1.0I1.1Before use, chemicals must be checked for shelf
life and/or expiration date.DailyConformingNAN/AI1.2Temperature ControllerPer
Section 3 Pyrometry (Daily per 3.3.1.2)ConformingAnnuallyConforming (All
controllers that are
capable)
I1.3ThermocouplePer Section 3 Pyrometry (N/A not referenced in any section
or table)ConformingPer Section 3PyrometryConformingI1.4pH MeterPer equipment
manufacturer's specificationsConformingAnnuallyConformingI1.5pH ProbeOnce every 4
hours, using a minimum of 2 buffer solutions
near the min and max of the chemical control range.*ConformingNAN/A1x per
DayI1.6Conductivity MeterPer equipment manufacturer's
specificationsConformingAnnuallyConformingI1.7Conductivity ProbeOnce every 4 hours,
using a minimum of 2 reference
solutions near the min and max of the chemical control
range.
N/ANAN/AI1.8Ion Selective (ISE ) ProbeOnce every 4 hours, using a minimum of 2
reference
solutions near the min and max of the chemical control
range.
N/ANAN/AI1.9Laboratory BalanceMonthly using a minimum of 2 reference mass
standards.ConformingAnnuallyConformingI1.10Atomic Absorption (AA)Before each
use.N/AAnnuallyN/AI1.11Inductively Coupled Plasma (ICP)Before each
use.ConformingAnnuallyConformingI1.12Ion Chromatography (IC)Before each
use.N/AAnnuallyN/AI1.13X-Ray Fluorescence (XRF)
Daily.
Thickness and alloy for each combination of plating and
substrate.
ConformingAnnuallyConformingI1.14Hardness
TesterDailyN/AAnnuallyN/AI1.15ProfilometerDailyN/AAnnuallyN/AI1.16Lab
RectifierNAN/AAnnuallyConformingI1.17Hand held digital
thermometerNAN/AAnnuallyConformingI1.18Glass thermometerVisual inspection before
each use.N/AAnnuallyN/AI1.19Pipettes - Before use, pipettes must be checked
for broken tipsBefore each useConformingNAN/AI1.20Salt Spray
CabinetDailyConformingAnnuallyConformingI1.21Thickness TesterEvery 8
hoursConformingAnnuallyConformingI1.22CASS
CabinetDailyN/AAnnuallyN/AI1.23Microscope (Min 100X) with calibrated grid reticle
for Pore/Crack CountDailyN/AAnnuallyN/AI1.24Lab OvenPer Section 3 Pyrometry (Once
every 6 Months per 3.3.1.1)ConformingAnnuallyConformingI1.25Torque-tension/Friction
Tester
NAN/AAnnuallyN/AI1.26RefractometerMonthlyN/ANAN/AI1.27SpectrophotometerMonthlyN/AAn
nuallyN/AI1.28Color MeterDailyN/AAnnuallyN/AI1.29Gloss
MeterMonthlyN/AAnnuallyN/AI1.30Digital Temperature Recorder (i.e.,
DataPaq)NAN/AAnnuallyN/A

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What processes are performed at the facility?

What processes are performed at the facility?

What equipment is used to verify process control?

What equipment is used to verify process control?

CQI-11

Special Process: Plating System Assessment

Number of Plating Employees at this Facility: 54

Captive Plater (Y/N): NCommercial Plater (Y/N): Y

Date of Assessment: 7/1/2020Date of Previous Assessment: 1/1/2020Date of Re-

Process Table G:Process Table B:

Process Table H:Process Table C:

Process Table I:Process Table D:

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

Number of Nonconforming Findings in the Job Audit(s): 00

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

© 2019 AIAG (Automotive Industry Action Group) 1

1.1• To ensure readily available expertise, there shall be a dedicated and

Are special characteristics, as defined by the organization and its customers,

1.9GuidanceWhat is the process to retain these records?

Describe the continual improvement process used to achieve improvements in quality

• The organization shall provide employee training for all operations.

Describe the process for reporting problems.

2.1It is critical that all customer requirements and lot identification be

GuidanceWhere is the nonconforming holding area, and how is it identified?

How is the affected product traced, dispositioned and documented?

© 2019 AIAG (Automotive Industry Action Group) 25

ITEM #EQUIPMENT TYPEVerification FrequencyConformingNonconformingNACalibration /

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