CQI-11 Plating System Assessment

CQI-11
Special Process: Plating System Assessment

Version 1 Issued 8/07
Facility Name:
Address:
Phone Number: Type(s) of Plating Processing at this Facility:

Fax Number: Process Table A
Zinc
Number of Plating Employees at this Facility: Zinc Alloy Plating
Captive Plater (Y/N): Process Table B

Commercial Plater (Y/N): Surface Conditioning of
Metals for Decorative Plating
Date of Assessment: Process Table C

Surface Conditioning of ABS
& PCABS Plastics for
Decorative Plating
Date of Previous Assessment:
Process Table D
Decorative Plating
Process Table E
Mechanical Plating
Process Table F
Equipment
Process Equipment
Current Quality Certification(s):
Date of Re-assessment (if necessary):
Personnel Contacted:
Name: Title: Phone: Email;
Auditors/Assessors:
Name: Company: Phone: Email:
Number of "Not Satisfactory" Findings:
Number of "Needs Immediate Action" Findings:
Number of "Fail" Findings in the Job Audit(s):

CQI-11
Special Process: Plating Process Assessment (General Facility Overview)
Assessment
Question Not Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory
Number Satisfactory Action
Section 1 - Management Responsibility and Quality Planning
To ensure readily available expertise, there shall be a

dedicated and qualified plating person on the site.
This individual shall be a full-time employee and the
position shall be reflected in the organization chart. A
Is there a dedicated and job description shall exist identifying the qualifications
1.1 qualified plating person on- for the postition including chemical and plating
site? knowledge. The qualifications shall include a
minimum of 5 years experience in plating and surface
finishing or a combination of formal
chemistry/chemical engineering education and
plating experience totaling a minimum of 5 years.
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.
Does the plater perform
1.2 After the part approval process is approved by the
advanced quality planning?
customer, no process changes are allowed unless
approved by the customer. The plater shall contact
the customer when clarification of process changes is
required. This clarification of process changes shall
be documented.
The organization shall incorporate the use of a

documented Failure Mode and Effects Analysis
(FMEA) procedure and ensure the FMEAs are
updated to reflect current part quality status.
The FMEA shall be written for each part or part family
Are plater FMEA's up to date or they may be process-specific and written for each
1.3 and reflecting current process. In any case, they shall address all process
processing? steps from part receipt to part shipment and all key
plating process parameters as defined by the
organization. A cross-functional team shall be used in
the development of the FMEA. All characteristics, as
defined by the organization and its customers, shall
be identified, defined, and addressed in the FMEA.
CQI-11
Assessment

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
plating process parameters as defined by the
Are finish process control organization. A cross-functional team, including a
1.4 plans up to date and reflecting production operator, shall be used in the
current processing? 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. 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.
To ensure all customer requirements are both

understood and satisfied, the organization shall have
all related plating 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
Are all plating related and organization shall have a process to ensure the
referenced specifications timely review, distribution, and implementation of all
current and available? For customer and industry engineering standards and
1.5
example: SAE, AIAG, ASTM, specifications and changes based on customer-
General Motors, Ford, and required schedule. This process shall be executed
DaimlerChrysler. 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.
CQI-11
Assessment

The plater shall have written process specifications

for all active processes and identify all steps of the
process including relevant operating parameters.
Examples of operating parameters include process
temperatures, cycle times, load rates, rectifier
Is there a written process settings, etc. Such parameters shall not only be
1.6 specification for all active defined, they shall have operating tolerances as
processes? 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.
To demonstrate each process is capable of yielding

acceptable product the organization shall perform
product capability studies for the initial validation of
each process, after relocation of any process
equipment, and after a major rebuild of any
equipment. The organization shall define what
constitutes a major rebuild. Initial product capability
studies shall be conducted for all plating processes
per line as defined in scope of work and in
Has a valid product capability
accordance with customer requirements. Capability
1.7 study been performed initially
study techniques shall be appropriate for the plating
and after process change?
product characteristics, e.g. plate thickness,
corrosion resistance, etc.. 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 be followed in case capability indices fall
outside customer requirements or established
ranges.
CQI-11
Assessment

The analysis of products and processes over time

can yield vital information for defect prevention
efforts. The organization shall have a system to
Does the plater collect and
collect, analyze, and react to product or process data
analyze data over time, and
1.8 over time. Methods of analysis shall include ongoing
react to this data?
trend or historical data analysis of special product or
process parameters. The organization shall
determine which parameters to include in such
analysis.
Management shall review the oven monitoring

Does management review systems/logs at intervals not to exceed 24 hours or
and verify bake oven logs for prior to parts being released for shipment. The plater
1.9 parts requiring hydrogen shall have reaction plans for non-conformances to
embrittlement relief every 24 process requirements. This is to contain, at
hours? minimum, requirements for quarantining material and
notifying customer.
Are internal assessments The organization shall conduct internal assessments

being completed on an annual on an annual basis, at a minimum, using the AIAG
1.10
basis, at a minimum, PSA. Concerns shall be addressed in a timely
incorporating AIAG PSA? manner.
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
Is there a system in place to well as those characteristics for which reprocessing is
1.11 authorize reprocessing and is not permissible. All reprocessing activity shall
it documented? require a new processing control sheet issued by
qualified technical personnel denoting the necessary
plating 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.
CQI-11
Assessment

The quality management system shall include a

Does the Quality Department
process for documenting, reviewing, and addressing
review, address, and
1.12 customer concerns and any other concerns internal
document customer and
to the organization. A disciplined problem-solving
internal concerns?
approach shall be used.
The plater shall define a process for continual

improvement for each plating process identified in the
Is there a continual scope of the PSA. The process shall be designed to
improvement plan applicable bring about continual improvement in quality and
1.13
to each process defined in the productivity. Identified actions shall be prioritized and
scope of the assessment? shall include timing (estimated completion dates).
The organization shall show evidence of program
effectiveness.
Does the Quality Manager or

The Quality Manager or designee is responsible for
designee authorize the
1.14 authorizing and documenting appropriate personnel
disposition of material from
to disposition quarantine material.
quarantine status?
There shall be procedures and work instructions

available to plating personnel covering the plating
process. These procedures or work instructions shall
Are there procedures or work
include methods of addressing potential emergencies
instructions available to
1.15 (such as power failure), equipment start-up,
plating presonnel that define
equipment shut-down, product segregation (See 2.8),
the plating process?
product inspection, and general operating
procedures. These procedures or work instructions
shall be accessible to shop floor personnel.
The organization shall provide employee training for

all plating operations. All employees, including
backup and temporary employees, shall be trained.
Documented evidence shall be maintained showing
Is management providing
1.16 the employees trained and the evidence shall include
employee training for plating?
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.
CQI-11
Assessment

The organization shall maintain a responsibility matrix
identifying all key management and supervisory
Is there a responsibility matrix
functions and the qualified personnel who may
to ensure that all key
perform such functions. It shall identify both primary
1.17 management and supervisory
and secondary (backup) personnel for the key
functions are performed by
functions (as defined by the organization). This
qualified personnel?
matrix shall be readily available to management at all
times.
The organization shall have a documented

preventive maintenance program for key process
equipment (as identified by the organization). The
program shall be a closed-loop process that tracks
maintenance efforts from request to completion to
Is there a preventive
assessment of effectiveness. Equipment operators
maintenance program? Is
shall have the opportunity to report problems, and
maintenance data being
1.18 problems shall also be handled in a closed-loop
utilized to form a predictive
manner. Company data, e.g., downtime, quality
maintenance program?
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 predictive
maintenance program.
Has the plater developed a

The plater shall develop and maintain a critical spare
critical spare part list and are
1.19 parts list and shall ensure the availability of such
the parts available to minimize
parts to minimize production disruptions.
production disruptions?
CQI-11
Assessment

Section 2 - Floor and Material Handling Responsibility

Does the facility ensure that
Documented processes and evidence of compliance
the data entered in the
shall exist, e.g., shop travelers, work orders, etc. The
2.1 receiving system matches the
facility shall have a detailed process in place to
information on the customer's
resolve receiving discrepancies.
shipping documents?
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
Is product clearly identified
all required operations are performed. Customer
2.2 and staged throughout the
product shall be clearly identified and staged
plating process?
throughout the plating process. Non-plated, in-
process, and finished product shall be properly
segregated and identified. All material shall be
staged in a dedicated and clearly defined area.
Out-going lot(s) shall be traceable to the incoming
Is lot traceability and integrity lot(s). The descipline of precisely identifying lots and
2.3 maintained throughout all linking all pertinent information to them enhances the
processes? ability to do root cause analysis and continual
improvement.
The control of suspect or non-conforming product is

necessary to prevent inadvertent shipment or
contamination of other lots. Procedures shall be
Are procedures adequate to adequate to prevent movement of non-conforming
prevent movement of non- product into the production system. Procedures shall
2.4
conforming product into the exist addressing proper disposition, product
production system? identification and tracking of material flow in and out
of hold area. Non-conforming hold area shall be
clearly designated to maintain segregation of such
material.
Is there a system to identify

trap points in the entire plating The plater shall have documented procedures to
process to reduce risk of identify and monitor trap points for each
2.5
mixed parts (inappropriate, process/equipment. Monitoring of potential trap
unfinished, or improperly points shall occur for every part changeover.
plated parts)?
Containers handling customer product shall be free

of inappropriate material. After emptying and before
re-using containers, containers shall be inspected to
Are containers free of ensure that all parts and inappropriate material have
2.6
innappropriate material? been removed. The source of inappropriate material
shall be identified and addressed. This is to ensure
that no nonconforming plating parts or inappropriate
material contaminate the finished lot.
CQI-11
Assessment

Loading parameters shall be specified, documented

Is part loading specified,
2.7 and controlled. Examples include parts per rack and
documented and controlled?
load size.
Unplanned or emergency downtime greatly raises the

risk of improper processing. Operators shall be
trained in material handling, containment action, and
Are operators trained in product segregation in the event of an equipment
material handling, emergency including power failure. Training shall be
containment action and documented. Work instructions specifically
2.8 product segregation in the addressing potential types of equipment emergencies
event of an equipment and failures shall be accessible to and understood by
emergency including power equipment operators. These instructions shall
failure? address containment/reaction plans related to all
elements of the process. Evidence shall exist
showing disposition and traceability of affected
product.
Is the handling, storage and The plater's loading/unloading systems, in process

2.9 packaging adequate to handling and shipping process shall be assessed for
preserve product quality? risk of part damage or other quailty concerns.
Plant cleanliness, housekeeping, environmental, and

working conditions shall be conducive to controlling
Are plant cleanliness,
and improving quailty. The plater should evaluate
housekeeping and
such conditions and their effect on quality. A
2.10 environmental and working
housekeeping policy shall be clearly defined and
conditions conducive to
executed. The facility shall be reviewed for the
control and improved quality?
following items: loose parts on floor; spillage around
tanks; overall plant lighting; fumes etc.
Process control parameters shall be monitored per

Are process control frequencies specified in Process Tables. Computer
parameters monitored per monitoring equipment with alarms and alarm logs
2.11
frequencies specified in satisfy the verification requirement. A designated
Process Tables? floor person shall verify the process parameters, e.g.,
by initialing a strip chart or data log.
CQI-11
Assessment

Are there documented reaction plans to both out of

Are out of control/specification
control and out of tolerance process parameters? Is
2.12 parameters reviewed and
there documented evidence that reaction plans are
reacted to?
followed?
Are In-Process / Final Test In-Process / Final Test Frequencies shall be

2.13 Frequencies performed as performed as specified in Process Tables. Refer to
specified in Process Tables? Process Tables.
Test equipment shall be verified/calibrated per

applicable customer specific standard or per an
applicable consensus standard, e.g., ASTM, SAE,
Is product test equipment
2.14 ISO, NIST, etc. Verification/calibration results shall
verified?
be internally reviewed, approved and documented.
Refer to Process Tables for frequency of checks.

CQI-11
Section 3 - Zinc/ Zinc Alloy Plating Equipment

Assessment
Question Needs Immediate
Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action
Does plating line have Refer to Process Table F for equipment
3.1 proper process control requirements.
equipment?
A system shall be used by the plating

facility to track calibration dates of
equipment. This system will typically be
a computerized tracking system or other
Are process and testing notification system. Test equipment
equipment calibrations shall be verified/calibrated per applicable
3.2
and/or verification certified, customer specific standard or consensus
posted, and current? standard, e.g., ASTM, SAE, ISO, NIST,
etc. Verification/calibration results shall
be internally reviewed, approved and
documented.
Supplier shall have preventative

Are barrels, racks, and
3.3 maintenance system that is documented
baskets maintained?
and implemented.

3.4 Are rectifiers maintained? maintenance system that is documented
and implemented.
Uniformity survey must show that ovens

were tested both empty and with a
For hydrogen embrittlement
dense load. Parts must come up to
relief ovens, are
3.5 temperature within one hour of entering
temperature uniformity
oven and meet temperature tolerance
surveys performed yearly?
specified by customer.
For hydrogen embrittlement Supplier shall have preventative

relief ovens, are maintenance system that is documented
3.6
thermocouples checked and implemented.
and/or replaced quarterly?
CQI-11
Section 4 - Decorative (Cu, Ni, Cr) Plating Equipment

Assessment
Question Needs
Question Requirements and Guidance Objective Evidence Not
Number N/A Satisfactory Immediate
Satisfactory
Action
Does plating line have
Refer to Process Table F for equipment
4.1 proper process control
requirements.
equipment?
A system shall be used by the plating

facility to track calibration dates of
equipment. This system will typically be
a computerized tracking system or other
notification system. Test equipment shall
Are process and testing
be verified/calibrated per applicable
equipment calibrations
4.2 customer specific standard or
and/or verification certified,
consensus standard, e.g., ASTM, SAE,
posted, and current?
ISO, NIST, etc. Verification/calibration
results shall be internally reviewed,
approved and documented. Refer to
Process Table F, for equipment
certification time table

4.3 Are racks maintained? maintenance system that is documented
and implemented.
4.4 Are rectifiers maintained? maintenance system that is documented
and implemented.
4.5 Are filters maintained? maintenance system that is documented
and implemented.
Is all other applicable
4.6 maintenance system that is documented
equipment maintained?
and implemented.
For all thermocouples/ Supplier shall have preventative
4.7 thermometers are they maintenance system that is documented
checked and/or replaced? and implemented.
Checks shall be documented. Each
Are the process and alarm shall be reviewed independently
4.8 equipment alarm checks for functionality if applicable. Plater
being tested? shall have a list of alarms relevant to
process.
CQI-11
Section 5 - Job Audit - Finished Product Review
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Plating Requirements:
Question Related Customer or Internal Job (Shop) Order or Reference Actual Condition Pass /
Job Audit Question
# PSA Question # Requirement Documentation Requirement (Objective Evidence) Fail / N/A
5.1 Are contract review, advance 1.2
quality planning, FMEA, control 1.3
plans, etc., performed by qualified 1.4 N/A
individuals? 1.17
5.2 Does the plater have the proper 1.5 N/A

customer specifications for the
part?
5.3 Is a shop traveler created to meet 1.6
customer requirements? 2.1
5.4 Is material identification (part 2.2
numbers, lot numbers, contract 2.3
numbers, etc.) maintained 2.4
throughout the plating process?
5.5 Is there documented evidence of 2.1
Receiving Inspection?
5.6 1.6
Are the Loading / Racking 2.7
requirements identified? 2.9
5.7
Is the proper procedure or
process specification used? 1.5
Refer to Process Tables for 1.6
specific parameters. List 2.1
parameters that were verified in 2.11
this audit in the spaces provided 2.13
below.
CQI-11
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Job Audit Question
CQI-11
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Job Audit Question
5.8 2.13 Each part may have one or more requirements determined by the plating
What are the product inspection specification. Parts must meet each requirement. List each requirement below and
requirements? validate.
5.8.1 Requirement: Plate Thickness
Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
Requirement: Corrosion
5.8.2 Resistance
Test Method:
Specification:
Requirement: Hydrogen
5.8.3 Embrittlement Relief (if
Applicable)
Test Method:
Specification:
5.8.4 Requirement: Adhesion Test
Test Method:
Specification:
5.8.5 Requirement: Alloy (if Applicable)
Test Method:
Specification:
CQI-11
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Job Audit Question
5.8.6 Requirement: Torque Tension (if
Applicable)
Test Method:
Specification:
5.8.7 Requirement: Appearance
(Decorative)
Test Method:
Specification:
Requirement: S.T.E.P.
5.8.8 (Decorative)
Test Method:
CQI-11
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Job Audit Question
Specification:
5.8.9 Requirement: Pore Count/Size
(Decorative)
Test Method:
Specification:
5.8.10 Requirement: Ductility by foil
(Decorative)
Test Method:
Specification:
5.8.11 Requirement: Internal Stress
(Decorative)
Test Method:
Specification:
5.8.12 Requirement:Thermal Cycle
(Decorative Plastic)
Test Method:
Specification:
CQI-11
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Job Audit Question
Operator or Inspector Responsibilities
5.9 Were appropriate process steps 1.4
signed off? 2.2
2.3
2.11
5.10 1.2
Were all inspection steps, as 1.4
documented in the control plan
performed?
5.11 1.2
Were steps/operations performed 1.4
that were not documented in the 1.6
control plan?
5.12 If additional steps were 1.2

performed, were they authorized? 1.4
1.6
1.11
1.17
5.13 If the order was certified, did the 2.11
certification accurately reflect the 2.13
process performed?
5.14 Was the certification signed by an 1.17
authorized individual?
5.15 Are the parts and containers free 2.6
of foreign objects or
Packaging Requirements
5.16 Are packaging requirements 2.9
identified?
CQI-11
Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Material:
Job Audit Question
5.17 Are parts packaged to minimize 2.9
mixed parts (parts packed over
height of container)?
Shipping Requirements
5.18 Were the parts properly 2.3
5.19 Were the containers properly 2.3
labeled? 2.9
CQI-11
PROCESS TABLE A - Zinc - Zinc Alloy Plating

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 plater is conforming to customer requirements.
ITEM # Related PSA Category/Process Steps Control Monitoring

Question #
1.0 Metal Cleaning
Type:
Size,volume:
Proprietary name:
Chemical supplier:
A1.1 1.4; 2.11; 2.13 Temperature Automatic 1/Shift
A1.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/Day
A1.3 1.4; 2.11; 2.13 Time Per Tech Data Sheet Per Process Sheet
A1.4 Agitation Per Tech Data Sheet Per Process Sheet
A1.5 1.4; 2.11; 2.13 Current/Voltage (As applicable) Automatic 1/Shift
A1.6 Solution Level Automatic or Manual 1/Shift
A1.7 Rinse Process Sheet 1/Shift
2.0 Acid
Type:
Size,volume:
Proprietary name:
Chemical supplier:
A2.1 1.4; 2.11; 2.13 Temperature - Optional Automatic 1/Shift
A2.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/Shift
A2.3 1.4; 2.11; 2.13 Time (Less than 10 Minutes or Customer Automatic Continuous
Specific)
A2.4 Inhibitor Per Tech Data Sheet N/A
A2.5 Solution Level Automatic or Manual 1/Shift
A2.6 Rinse Process Sheet 1/Shift
3.0 Acid Plating Bath
Type:
Size,volume:
Proprietary name:
Chemical supplier:
A3.2 1.4; 2.11; 2.13 Time Automatic 1/Shift
A3.3 1.4; 2.11; 2.13 Current/Voltage Automatic 1/Shift
A3.4 Chloride Concentration Manual 1/Day
A3.5 pH Automatic or Manual 1/Shift
A3.6 Plating Test Cell (Hull) Manual 1/Day
A3.7 Metal Concentration(s) Automatic or Manual 1/Day
A3.8 Buffer (Ammonia / Boric Acid per TDS) Manual 1/Day
A3.9 Filtration Continuous 1/Shift
A3.10 Agitation (Rack only - others optional) Continuous 1/Shift
A3.11 Rinse Per Process Sheet 1/Shift
CQI-11
PROCESS TABLE A - Zinc - Zinc Alloy Plating


Question #
4.0 Alkaline Plating Bath
Type:
Size,volume:
Proprietary name:
Chemical supplier:
A4.2 1.4; 2.11; 2.13 Time Automatic 1/Shift
A4.3 1.4; 2.11; 2.13 Current/Voltage Automatic 1/Shift
A4.4 Caustic Concentration Manual 1/Day
A4.5 Plating Test Cell (Hull) Manual 1/Day
A4.6 Metal Concentration(s) Automatic or Manual 1/Day
A4.7 Filtration Continuous 1/Shift
5.0 Hydrogen Embrittlement Relief
3.6 Oven Type:
3.6 Oven Temperature:
6.0 Passivates
Type:
Size,volume:
Proprietary name:
Chemical supplier:
A6.1 Acid Activation Per Control Plan N/A
A6.1.1 - Concentration Automatic or Manual 1/Shift
A6.1.2 1.4; 2.11; 2.13 - Time Automatic or Manual 1/Shift
A6.2 Passivate Per Control Plan N/A
A6.2.1 - Concentration Automatic or Manual 1/Shift
A6.2.2 1.4; 2.11; 2.13 - Temperature Automatic or Manual 1/Shift
A6.2.3 1.4; 2.11; 2.13 - Time Automatic or Manual 1/Shift
A6.2.4 - pH Automatic or Manual 1/Shift
A6.2.5 - Agitation Automatic or Manual 1/Shift
A6.2.6 - Contamination (e.g. Fe, Zn) Per Process Sheet 1/week
A6.4 Dry Per Tech Data Sheet Per Process Sheet
7.0 Supplemental Treatments - Sealers and
Torque Tension Modifiers
A7.1 Concentration Automatic or Manual Per Control Plan and
TDS
A7.2 1.4; 2.11; 2.13 Solution Temperature Automatic Per Control Plan and
TDS
A7.3 1.4; 2.11; 2.13 Time Automatic or Manual Per Control Plan and
TDS
A7.4 pH Automatic or Manual Per Control Plan and
TDS
A7.5 Drying Temperature Automatic Per Control Plan and
TDS
A7.6 Spin Speed Automatic Per Control Plan and
TDS
A7.7 Agitation Automatic or Manual Per Control Plan and
TDS
CQI-11
PROCESS TABLE B - Surface Conditioning of Metals for Decorative

Plating

Question #
1.0 Polishing and Buffing
B1.1 Manual
B1.2 Automatic
B1.3 Steel
B1.4 Stainless Steel
B1.5 Aluminum
B1.6 Zinc diecast
2.0 Metal Cleaning
Type:
Size,volume:
Proprietary name:
Chemical supplier:
B2.1 1.4; 2.11; 2.13 Temperature Automatic 1/Shift
B2.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/Shift
B2.3 1.4; 2.11; 2.13 Time Per TDS Per process sheet
B2.4 Agitation - Optional Per TDS Per process sheet
B2.5 4.4 Current/Voltage (As applicable) Automatic 1/Shift
B2.6 Solution Level Automatic or Manual 1/Shift
B2.7 Rinse Process Sheet 1/Shift
3.0 Pretreatment
B3.1 Strike (As applicable) N/A N/A
B3.1.1 1.4; 2.11; 2.13 - Temperature Automatic 1/Shift
B3.1.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/Shift
B3.1.3 1.4; 2.11; 2.13 - Time Automatic Per process sheet
B3.1.4 - Agitation - Optional Per TDS Per process sheet
B3.1.5 4.4 - Current/Voltage (if applicable) Automatic 1/Shift
B3.1.6 - Solution Level Automatic or Manual 1/Shift
B3.1.7 - Rinse Process Sheet 1/Shift
B3.2 Zincate (Aluminum Only) N/A N/A
B3.2.1 1.4; 2.11; 2.13 - Temperature Automatic 1/Shift
B3.2.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/Shift
B3.2.3 1.4; 2.11; 2.13 - Time Automatic Per process sheet
B3.2.4 - Agitation - Optional Per TDS Per process sheet
B3.2.5 - Solution Level Automatic or Manual 1/Shift
B3.2.6 - Dump Schedule Per TDS Per process sheet
B3.2.7 Rinse Process Sheet 1/Shift
CQI-11
PROCESS TABLE B - Surface Conditioning of Metals for Decorative

Plating

Question #
4.0 Acid
Type:
Size,volume:
Proprietary name:
Chemical supplier:
B4.1 1.4; 2.11; 2.13 Temperature - Optional Automatic 1/Shift
B4.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/Shift
B4.3 1.4; 2.11; 2.13 Time (Per Specification) Automatic Continuous
B4.4 Solution Level Automatic or Manual 1/Shift
B4.5 Rinse Process Sheet 1/Shift
(Proceed to Process Table D - Decorative Plating)

CQI-11
PROCESS TABLE C - Surface Conditioning of ABS & PCABS Plastic

for Decorative Plating

Question #
1.0 Cleaning and Pre-Etch (If Applicable)
Type:
Size,volume:
Proprietary name:
Chemical supplier:
C1.1 1.4; 2.11; 2.13 Temperature Automatic 1/Shift
C1.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/Shift
C1.3 1.4; 2.11; 2.13 Time Automatic Per process sheet
C1.4 Agitation Per TDS Per process sheet
C1.5 Solution Level Automatic or Manual 1/Shift
C1.6 Rinse Process Sheet 1/Shift
2.0 Etch
Type:
Size,volume:
Proprietary name:
Chemical supplier:
3.0 Neutralizer
Type:
Size,volume:
Proprietary name:
Chemical supplier:
CQI-11
PROCESS TABLE C - Surface Conditioning of ABS & PCABS Plastic

for Decorative Plating

Question #
4.0 Activator
Type:
Size,volume:
Proprietary name:
Chemical supplier:
5.0 Accelerator
Type:
Size,volume:
Proprietary name:
Chemical supplier:
6.0 Electroless Plating
Type:
Size,volume:
Proprietary name:
Chemical supplier:
C6.1 1.4; 2.11; 2.13 - Temperature Automatic 1/Shift
C6.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/Shift
C6.3 1.4; 2.11; 2.13 - Time Automatic Per process sheet
C6.4 - Agitation Per TDS Per process sheet
C6.5 - Solution Level Automatic or Manual 1/Shift
C6.6 - Rinse Process Sheet 1/Shift
7.0 Electrolytic Plating - Strike
Type:
Size,volume:
Proprietary name:
Chemical supplier:
C7.1 1.4; 2.11; 2.13 - Temperature Automatic 1/Shift
C7.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/Day
C7.3 4.1, 4.4 - Current Automatic 1/Shift
C7.4 1.4; 2.11; 2.13 - Time Automatic 1/Shift
C7.5 - Agitation Per TDS 1/Shift
C7.6 - Solution Level Automatic or Manual 1/Shift
C7.7 - Rinse Process Sheet 1/Shift
CQI-11
PROCESS TABLE D - Decorative Plating


Question #
1.0 Acid Copper (as applicable)
Type:
Size,volume:
Proprietary name:
Chemical supplier:
D1.1 1.4; 2.11; 2.13 Temperature Automatic 1/Shift
D1.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/Shift
D1.3 1.4; 2.11; 2.13 Time Automatic Per process sheet
D1.4 Agitation Per TDS Per process sheet
D1.5 4.1, 4.4 Current/Voltage Per Process Sheet Per Job
D1.6 Solution Level Automatic or Manual 1/Shift
D1.7 Rinse Per Process Sheet 1/Shift
D1.8 Filtration Continuous 1/Shift
D1.9 Post Clean Per Process Sheet 1/Day
2.0 Semi-Bright Nickel
Type:
Size,volume:
Proprietary name:
Chemical supplier:
D2.7 4.2 pH Automatic 1/Shift
D2.8 4.2 Internal stress test Manual 1/Month
D2.9 4.2 Ductility test Manual 1/Month
D2.10 4.2 Sulfur Concentration (as deposited) Manual 1/Month
3.0 High Activity Nickel (as applicable)
Type:
Size,volume:
Proprietary name:
Chemical supplier:
D3.7 pH Automatic 1/Shift
D3.8 Filtration Continuous Per process sheet
CQI-11
PROCESS TABLE D - Decorative Plating


Question #
4.0 Bright Nickel
Type:
Size,volume:
Proprietary name:
Chemical supplier:
D4.5 4.1,4.4 Current/Voltage Per Process Sheet Per Job
D4.7 pH Automatic 1/Shift
D4.8 Internal stress test Manual 1/Month
D4.9 Ductility test Manual 1/Month
5.0 Microporous Nickel
Type:
Size,volume:
Proprietary name:
Chemical supplier:
D5.3 1.4; 2.11; 2.13 Time Automatic Per Process Sheet
D5.4 Agitation Per TDS Per Process Sheet
D5.7 4.2 pH Automatic 1/Shift
D5.9 4.2 STEP Test (of final product) Manual 1/Day
6.0 Chromium
Type:
Size,volume:
Proprietary name:
Chemical supplier:
D6.3 1.4; 2.11; 2.13 Time Automatic Per Process Sheet
D6.4 Agitation (if applicable) Per TDS Per Process Sheet
D6.8 4.2 Pore Count and Pore Size Manual 1/Day
CQI-11
PROCESS TABLE E - Mechanical Plating

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.
ITEM # Related PSA

Question # Category/Process Steps Control Monitoring
1.0 Metal Cleaning (Off Line)
E1.1 1.4; 2.11; 2.13 Temperature Automatic 1/Shift

E1.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/Shift
E1.3 1.4; 2.11; 2.13 Time Automatic or Manual Per Process Sheet
E1.4 Agitation Per TDS Per Process Sheet
E1.5 Solution Level Automatic or Manual 1/Shift
E1.6 Rinse Per Process Sheet 1/Shift
2.0 Mechanical Plating
E2.1 Load Size (e.g. weight, area, volume) Per Process Sheet per load
E2.2 Water Volume Per Process Sheet per load
E2.3 1.4; 2.11; 2.13 Temperature Per Process Sheet per load
E2.4.1 Media Mix (Ratio) - Sieve Testing Per Process Sheet 1 x per week
E2.4.2 Media (Load Volume) Per Process Sheet per load
E2.4.3 Media (Cleanliness - To Avoid Per Process Sheet 1 x per week
Contamination)
E2.5.1 Surface Conditioner (Volume or weight) Per Process Sheet per load
E2.5.2 Surface Conditioner (Time) Per Process Sheet per load
E2.6.1 Surface preparation (Volume or weight) Per Process Sheet per load
- Cu Flash
E2.6.2 Surface preparation (Time) Per Process Sheet per load
E2.7.1 Promoter(s) (Volume) Per Process Sheet per load

E2.7.2 Promoter (Time) Per Process Sheet per load
E2.8.1 Zinc Flash (Weight or volume) Per Process Sheet per load
E2.8.2 Zinc Flash (Time) Per Process Sheet per load

E2.9.1 Metal Addition (Weight or volume) Per Process Sheet per load
E2.9.2 Metal Addition (Number of Adds) Per Process Sheet per load
E2.10 3.2 pH adjustments (Dependent on Adds) Per Process Sheet as needed
E2.11 Metal (Thickness) Per Process Sheet per load
E2.12 Water Polish (time) Per Process Sheet per load
E2.13 Part/Media Separation Per Process Sheet per load
file:///conversion/tmp/activity_task_scratch/529556102.xls Page 28
CQI-11
PROCESS TABLE E - Mechanical Plating

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.
ITEM # Related PSA

Question # Category/Process Steps Control Monitoring
3.0 Passivates
E3.1 Acid Activation per Control Plan
E3.1.1 1.4; 2.11; 2.13 - Concentration Per Process Sheet 1/Shift
E3.1.2 1.4; 2.11; 2.13 - Time Per Process Sheet 1/Shift
E3.2 Passivate
E3.2.1 1.4; 2.11; 2.13 - Concentration Per Process Sheet 1/Shift
E3.2.2 1.4; 2.11; 2.13 - Temperature Per Process Sheet 1/Shift
E3.2.3 1.4; 2.11; 2.13 - Time Per Process Sheet 1/Shift
E3.2.4 3.2 - pH Per Process Sheet 1/Shift
E3.2.5 - Agitation Per Process Sheet 1/Shift
E3.2.6 - Contamination (e.g. Fe, Zn) Per Process Sheet 1/week
E3.3 Rinse Per Process Sheet 1/Shift

E3.4 Dry Per Process Sheet Per Process Sheet
4.0 Supplemental Treatments - Sealers
and Torque Tension Modifiers
E4.1.1 1.4; 2.11; 2.13 - Concentration Automatic or Manual Per Control Plan and
TDS
E4.1.2 1.4; 2.11; 2.13 - Solution Temperature Automatic or Manual Per Control Plan and
TDS
E4.1.3 1.4; 2.11; 2.13 - Time Automatic or Manual Per Control Plan and
TDS
E4.1.4 3.2 - pH Automatic or Manual Per Control Plan and
TDS
E4.1.5 - Drying Temperature Automatic Per Control Plan and
TDS
E4.1.6 - Spin Speed Automatic Per Control Plan and
TDS
- Agitation Automatic or Manual Per Control Plan and
TDS
E4.1.7
file:///conversion/tmp/activity_task_scratch/529556102.xls Page 29
CQI-11
PROCESS TABLE F - EQUIPMENT

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. The
auditor shall verify plater is conforming to customer requirements.
LABORATORY EQUIPMENT
ITEM # Related PSA Zinc/Zinc Decorative EQUIPMENT TYPE Verification Calibration
Question # Alloy Plating Frequency Frequency
F1 2.14; 3.1; 4.1; 4.2 X X pH Meter/Probe Daily Yearly
F1.2 2.14; 3.1; 4.1; 4.2 X X Wet Analysis N/A N/A
F1.3 2.14; 3.1; 4.1; 4.2 X X Atomic Absorption (Optional)
MINIMUM REQUIRED TESTING CAPABILITY
F1.4 3 X Salt Spray Cabinet N/A Yearly
F1.5 3.2 & 4.2 X X Thickness Tester Daily Yearly
F1.6 2.14; 3.1; 4.1; 4.2 X STEP N/A Yearly
F1.7 2.14; 3.1; 4.1; 4.2 X CASS N/A Yearly
F1.8 2.14; 3.1; 4.1; 4.2 X Microscope N/A Yearly
F1.9 2.14; 3.1; 4.1; 4.2 X Freezer (POP only) N/A Yearly
F1.10 2.14; 3.1; 4.1; 4.2 X Lab Oven (POP only) N/A Yearly
F1.11 2.14; 3.1; 4.1; 4.2 X Stress (External Testing Acc.) N/A Yearly
F1.12 2.14; 3.1; 4.1; 4.2 X Sulfur by Foil (External Daily Yearly
Testing Acc.)
F2 2.14; 3.1; 4.1; 4.2 X Ductility (External Testing N/A Yearly
Acc.)
F2.1 2.14; 3.1; 4.1; 4.2 X Pore Count/Active Sites N/A N/A
F2.2 2.14; 3.1; 4.1; 4.2 X Pull Tester N/A Yearly
F2.3 3.2 & 4.2 X X Lab Rectifier N/A Yearly
PROCESS EQUIPMENT
ITEM PSA Clause Zinc & Decorative EQUIPMENT TYPE Verification Calibration
Number Zinc Alloy Plating Frequency Frequency
Plating
F3 X X Machine - Return type
automatic
3.3 & 4.3 X X Rack
Rack Size
3.3 X Barrel
Horizontal
Oblique
Barrel Size
-volume
-dimensions
F3.1 X X Hoist
Manual
Automatic
Rack Size
Barrel Size
F3.2 3.4 & 4.4 X X Rectifier Type
Water cooled
Air cooled
Amperage controlled
ITEM PSA Clause Zinc & Decorative Verification Calibration
Number Zinc Alloy Plating EQUIPMENT TYPE Frequency Frequency
Plating
Voltage controlled
CQI-11
PROCESS TABLE F - EQUIPMENT

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. The
auditor shall verify plater is conforming to customer requirements.
F3.3 X X Filters
Pre-pack
Cartridge
Other
F3.4 3.5 X Oven type
Continious
Batch
3.5 X Chart recorder
3.6 X Themocouples
number
3.3 X Basket type
Expanded metal
Perforated
Solid
Size
F3.5 X X Controllers
Automatic feeders
Timers
Temperature
Volume
F3.6 X X Agitation type
Air
Cathode rod
F3.7 X X Water source
Tap
RO
Deionized

CQI-11 Plating System Assessment

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CQI-11

Special Process: Plating System Assessment

Special Process: Plating System Assessment

Phone Number: Type(s) of Plating Processing at this Facility:

Captive Plater (Y/N): Process Table B

Date of Assessment: Process Table C

Current Quality Certification(s):

Date of Re-assessment (if necessary):

Number of "Not Satisfactory" Findings:

Number of "Needs Immediate Action" Findings:

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

Question Not Needs Immediate

Section 1 - Management Responsibility and Quality Planning

To ensure readily available expertise, there shall be a

The organization shall incorporate a documented

The organization shall incorporate the use of a

Special Process: Plating Process Assessment (General Facility Overview)

Question Not Needs Immediate

To ensure all customer requirements are both

Special Process: Plating Process Assessment (General Facility Overview)

Question Not Needs Immediate

The plater shall have written process specifications

To demonstrate each process is capable of yielding

Special Process: Plating Process Assessment (General Facility Overview)

Question Not Needs Immediate

The analysis of products and processes over time

Management shall review the oven monitoring

Are internal assessments The organization shall conduct internal assessments

The quality management system shall include a

Special Process: Plating Process Assessment (General Facility Overview)

Question Not Needs Immediate

The quality management system shall include a

The plater shall define a process for continual

Does the Quality Manager or

There shall be procedures and work instructions

The organization shall provide employee training for

Special Process: Plating Process Assessment (General Facility Overview)

Question Not Needs Immediate

The organization shall have a documented

Has the plater developed a

Question Not Needs Immediate

Section 2 - Floor and Material Handling Responsibility

The control of suspect or non-conforming product is

Is there a system to identify

Containers handling customer product shall be free

Special Process: Plating Process Assessment (General Facility Overview)

Question Not Needs Immediate

Loading parameters shall be specified, documented

Unplanned or emergency downtime greatly raises the

Is the handling, storage and The plater's loading/unloading systems, in process

Plant cleanliness, housekeeping, environmental, and

Process control parameters shall be monitored per

Special Process: Plating Process Assessment (General Facility Overview)

Question Not Needs Immediate

Are there documented reaction plans to both out of

Are In-Process / Final Test In-Process / Final Test Frequencies shall be

Test equipment shall be verified/calibrated per

Refer to Process Tables for frequency of checks.

Section 3 - Zinc/ Zinc Alloy Plating Equipment

A system shall be used by the plating