Col-27 Special Process: Casting System Assessment 1st Edition AIAG 2a insight. Expertise. Results. SetonAIAG 2a Speci Paces Cort Sate Asst The Gates Merson f lsued 10/2018 ABOUT AIAG Purpose Statement Founded in 1982, AIAG is = globally recognized organization where OEMs and suppliers unite to eddress: and resolve iscuss affecting the worldwide automstwe supply chain. AIAG's goals are to raduoa cast and complexity through ealisberation; improve product quality, health, safety end the environment, and optimize speed 16 market throughout the supply chain. AIAG Organization AIAG is made up of 3 board of directors, an executive director, executives on loan from member companies, associate directors, a full-ime staff. and volunteers serving on project teams. Directors, department managers, and program managers plan, direct and caordinate the association's activities under the ditection of the executive director. AIAG Projects ‘Volunteer committees focus en business processes or supporting technologies and methadolagies. They conduct research and develop, publish, and provide training on standards, conventions, standard business practices, white papers, and guidelines in the reas ef automatic identifcation, CAD/CAM, ED electronic commeree, continuous quality improvement, hesith focus, materials and project management, cecupationsl hesith & safety, retumable containers and packaging systems, transportetion/oustoms and truck & heavy equipment. “IEG PUBLICATIONS ‘An AIAG punicatan reflects a consensus oF hase substantally concemed wits scope and pronSiONs. An ‘ALSG pubicaton is rgended as gue f9 ald ie MaruSciurer, Pe consumer and the general pu, Te fexisfence ofan AIRG publesion does notin ary respect preclude anyone fom manufacturing, marketing, urnasing, o using Breau, processes, a paceaures not canfoming fo tre pubicaton. CAUTIONARY NOTICE sons are subject peice review and users are caufned fo obtain De latest eattons MAINTENANCE PROCEDURE FResogniang mat ms AIRS pupiestan may notcover Bi craymetances AIAG has estsnished = mamtenance procedure: lease reer tothe Ir the back ofS Oocurmard fe Submits USS! Pupitsnea oy: Auremoave nduszy Accon Group 128200 Lahser Road, Sule 200 ‘Sunhfialo, lohigan 48093 Bron: (248) 956-3570 » Fax: (240) 950-3259 APPROVAL STATUS. | Me avig quaity Steecng Communes anc-cesignatea stakehalvers approved ts worument fer pupicston 27 | cxooer 2015 | | | | | | | | | AIAG COPYRIGHT AND TRADEMARK NOTICE: ‘The cantents ofl pubishec' materia ae copyrighted by the Automotive Industy Acton Grovp uniess otherwise ndlcaled Sgpyantis oot cae as area afar eye Won recsedy 2 Se govern cfce! oy angles cs ser arte Beans oMGa) auees Al nan are preserved by AIAG, and contend may nat be eteied or ASSeMMnaed DUMSTEM C” PEARED In partafsucn content ‘Me infemation is nett be soln pavtar wale i atycre wenn your rganlzaton oF fo ancirer comzany: Copyright intingement is #vitson of deal aw sunject i crimal ard vl penalties. ISG and the Auda mest Acton (Group are regiterco sevice marks oftne Automadve Mausty Actan Greup, © 2015 Automate hasty Acton Group ISBN OF 7 OO8s¥ 387 0cQl-27 Special Process: Casting System Assessment Version 1, Issued 10015 FOREWORD Automotive Industry Action Group (ALAG) conumnittess are made up of volunteers frem mansber companies in the automotive industry. The work of preparing process audits is done by AIAG technical committees. This edition is 2 collaborative work of OEM, Tier I suppliers, and Casting suppliers. The main task of technical committees is to prepare Automotive Standards and System Requirements. Draft documents adopted by the technical committees are eizeulated to the Steering Committee and industry experts for review and consensus approval, Publication of the documents requires approval by ‘the Quality Steering Committee ACKNOWLEDGEMENTS The Quality Stesrinz Committee would like to acknowledge and thank the following individuals and their companies whe have contributed time and effort to the development of this document. Yulong Zhu Dana Holding Comporation Matt Otte Eaton Corporation Lin Zhang, FCA USLLC Brad Guthrie Ford Motor Company Jim Loeffler Ford Motor Company Tom Boone ‘Gensral Motors Company Devin Hess ‘Gensral Motors Company Yiwu Xu ‘General Motors Company Jairo Santana Volo Karen Whitmore AIAGAIAG 2 SpovlProces Cath Systm Ascer Tre Gaabyt ‘Verclon f, issued 102018 TABLE OF CONTENTS ABOUT AIAG. FOREWORD ACKNOWLEDGEMENTS. ‘TABLE OF CONTENT! INTRODUCTION .. Genera... - ssc vesceinnnn - PROCESS APPROACH, camgsieren assevern Goat ASSESEAIRNT PROCES. ne sets [ASSESSOR QUALIRCATIONS . — oe : (Ores RecuneMenTs, Score. Lica... SL2ApeUEATION.. 2 THE CASTING SYSTEM ASSESSMENT PROCEDURE. 2. INSTAUCTIONS FOR COMPLETING THE COVER SHEET Coven SHEE. on 2.2INETRUETON FoR COMPLET 1 CASTING SYSTEM ASSESSMENT ssc APPENDIX A.— PROCESS TABLES PROCESS TABLE A: DUCTILEIRON PROCESS TABLE E: GREYIRON PROCESS TABLE C: CENTRIFUGAL UNERS... PAGCESS TABLE 0: ALUMINUM SEML-PERNMIANENT MOLD PROCESS TABLE ALUMINUM SEMRL-PERMANENT MOLD CYLINOER HEADS PROCESS TABLE F: ALUMINUM GREEN SAND... PROCESS TAGLE G: INVESTMENT CASTING IRON/STEEL.onm-- PROCESS TABLE H: ALUMINUM HIGH PRESSURE THE CAST. ae - - PROCESS TABLE I: MAGNESIUM HIGH PRESSURE DIECAST... PROCESS TABLE J: ALUMINUM PERMANENT MOLD... on rs PROCESS TABLE K: ALUMINUM PISTON ncn vc : vn BB PROCESS TABLE L ZINCHIGH PRESSURE DIECAST scenic : a) PROCESS TABLE M: COMPACTED GRAPHITE IRON, a7 HERR a BEEBESper Poser csi syctan Asecement AIAG ‘essan 1, Issued 102015 tas INTRODUCTION General ‘The work of preparing CQI-27 Special Process: Casting System Assessment was carried out through the AIAG Casting Work Group. These casting requirements are complementary to customer and product standards, ‘The Castine System Assessment can be used to assess an organization’ ability to meet the requirements in this as it, a8 well.as customer, regulatory, and the organization's own requirements. The Casting ‘System Assessment can also be used between an organization and its suppliers Process Approach ‘The Casting System Assessment supports the automotive process approach 2: daseribad in ISO/TS 16548. Casting System Assessment Goals ‘The goal of the Casting System Assessment is the development ofa zobuat casting process by eliminating ‘common root causes of casting defects The Castine System Assessment, coupled with an intermaticnally recognized quality manazement system. and applicable customer-specfic requirements, defines the fundamental requirements for casting recesses. ‘The Casting System Assessment is intended to provide a common audit for automotive casting suppliers. Assessment Process ‘Ongoing assessmants shall be conducted ammually, unless otherwise specified by the customer, to reexamune the contimuing compliance with the Casting System Assessment. Each assessment shall include a review of the organization's systems using the Casting System Assessment. The assessment shall use ‘the process approach to auditing assessing 2s identified by the requirements of ISO/TS 16949,AIAG 2» Speast roees:Castng Systn Aunt The Catatt ‘Vereon 1, seve 102015 Assessor Qualifications Assessor(s) should have the following specific experience to conduct the Casting System a 1. Bean experienced quality management system (QMS) internal auditor (for example, ISO/TS 16949, ISO 9001). 2. Assessor should possess casting process knowledge. Evidence shall include a minimum of $ years! experience:in casting processes. 3. Assessor should possess knowledge of and be familiar with the application of automotive quality concepts including statistieal process control, measurement systems analysis, part approval, failure mode and effects analysis, and advanced quality planning. sment: NOTE: — Tfmore than one assessor is required to meet the shove qualifications, the lead assessor shall be the person meeting the requiements in #1 Other Requirements The organization shall keep records 2: evidanea of complianca to the raquiremonts identified in the Casting System Assessment, as well a all appropriate action plans to address any unsatisfactory ratings. These records shall be readily available for review by any customer requiring compliance to the requirements within this documentSpe Pree: Cat Syne Ansesnet AIAG ‘erin 1, eeued 102015 etalk 41 SCOPE 1.1 General This document specifies process requirements for casting suppliers, whe need to: * damonstrate ability to consistently provide product that meats customer and applicable regulstary requirements, and © enhance customer satisfaction through the effective application of the system, including processes for coutimual improvement of the system. The Casting System Assessmant is applicable to sites where customer-specified parts for production cice are processed throughout the automotive supply chain. lication All requirements of tho Casting System Assessment are ganarie and are intended to be applicable to all organizations performing the casting operations addressed in this document regardless of type, size, and product, Thirtean Process Tablas have bean developed and the appropriate tuble(s) isto be referenced during the assasemant. The Process Tables are spetific to casting processes.2s noted below © Process Table A ~ Ductile Iron © Procass Table B - Grey Iron © Process Table C ~ Centrifugal Liners © Process Table D ~ Alumizum Seni-Permanent Mold © Process Table E - Aluminum Semi-Permanent Mold Cylinder Heads © Process Table F — Aluminum Green Sand © Process Table G Investment Casting (Iron /Steel) © Process Table H — Aluminum Hizh Pressure Die Cast, © Brocass Table 1- Maznesfum High Prossure Die Cast, © Process Table J— Aluminum Permanent Mold © Procass Table K — Aluminum Piston © Process Table L ~ Zine High Pressure Die Cast, © Process Table M— Compacted Graphite IronAIAG Speci Proce: Cat Sten Arora Tre catty Vetson 1, fssued 102015 2 THE CASTING SYSTEM ASSESSMENT PROCEDURE 2.1 Instructions for Completing the Cover Sheet 1. Facility Name: Name of the foundry being assessed. The foundry may have several ‘buildings or physical locations in the same general area. The description must be clear about exactly which physical locations are being assessed 2 Address: The complete address of the foundry being assessed. Phoue Number: The phens number of the foundry, including Country Code. [there is mo common phone number for the foundry, the phone mumber of the Operations Manazer, Quality Manager, or Sales Manager shall be used, Website: The intemet website of the foundry. Number of Employees at this Foundry: The number of employees, salaried and hourly, associated with the casting operation at this foundry. 6 Date of Assessment: Enter the date(s) of the assessment Use 2 format which will avoid confusion. Example: May 3-4, 2016. Date of Previous Assessment: List the date of the previous Special Process: Casting System Assessment of this foundry 8. Type(s) of Casting at this Foundry: Place a checkmark te designate all casting process performed at this foundry. This information determines the appropriate Process Table that shall be used during the 2ssessment. Processes not listed om the cover sheet are not part of the Casting System Assessment. 9. Current Quality Certification(s): The foundry shall list their current quality certifications, for example, ISO/TS 16948, ISO $001. Certifications may be from 3nd party sources or customer quality certifications. [fcustomer quality certification is given, then the year of the last assessment by the customer shall also be given. 10. Date of Re-assessment (if necessary): [f“Fail” findings were observed from the original assessment, then the foundry shall address each item with implementation of the comresponding corrective action(s). The date of the re-assessment shall be given here, and the appropriate item(s) from the Process Tables, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the number of “Eail" findings shall be modified as appropriate. LL Personmel Contacted: List the name(s), title(s), phone mumiber(s), and email address(es), if available, of the principal participants fiom the foundry's organization. 12. Auditors/Assessors: List the nama(s), Company(ie:), phone number(s) and email address(es), ifavailable, of the auditor(s), 15, Number of “Fail” Findings: Enter the number of Fail” findings observed during the assesment. 14 Number of Process Table items identified as failed in Observations/Comments column: Enter fhe number of failed findings observed in the completed process tables.Coner a Special! 5 ed Drie Ae neemrert ‘version 1, sued 1005 Cover Sheet [Special Process: Casting = ara a ra Ps IN Pa STAIAG Spec Peco: Contin Stem hap Tee Catt Vorsion 1, tscbad 102015 2.2 Instructions for Completing the Casting System Assessment The assessor shall assess the Foundry’s compliance to all applicable Process Tables by comparing the ecidance presented by the foundry to the requirements listed in the “Minimum Requirement” columns. 1. Complete the Casting System Assessment, including all applicable Process Tables to determine the level of compliance 2. Address each “Fail” item and determine corrective action, including root eause analysis and inmplemntation of the corresponding corrective action(s). The correstive action(s) should be completed within 90 days. Records of the comective action, including verification, shall be maintained. Number of Process Table items identified as failed in Comments/Observation column to be repartad. 4, Assessments shall be conducted ammually. NOTE 1: Inthe Process Tables, the word “shall” indicates a requirement and the term “such a2 indicates that any suggestions given are for guidance only. “Should” indicates strongly recommanded NOTE 2: Han item is not applicable to the foundry, then the assessor shall write “M/A” in the “Pass/Fail Not Applicable” eclumn, and write 2 brief reason why itis uot applicable in the “Observations Comments about Actual Condition” column. Uf the observed evidence is in compliance to the item, the shall note the evidence in the “Observations/Comments about Actual Condition” column and write “Pass” in the “Pass/Fail/Not Applicable” cohm. If the observed evidence is not in compliance to the item, then the assessor shall note the non-compliance in the “Observations Comments zbout J.ctual Condition” columm and vutite “Fail” in the “Pass Fail Not Applicable” column, Ifthe assessor is not able to answer a question 2t the time of the audit, the assessor shall note the auissing information i the “Observations/Comments about Actual Condition” column and write“Fal” in the “Pass/Fail Not Applicable” column.CQl-27 Special Process: Casting System Assessment Version 1, tue 10015 APPENDIX A- PROCESS TABLES AIAG =cQl-27 Special Process: Casting System Assessment ‘Warsi 1, issued 192015 PROCESS TABLE A: DUCTILE IRON (BROOESS TABLE A= Dusiie kon festettrafeccstarstyaommnen menses henremm noencovmeegtecameneetnewrin tem wants ten en an denny ead Fivotorenmencte se a peas ace Arent aan hala Rope ey aT Tate nay apc oa a Ap mn Oa [onsite he capo sue: em | ColegoryPracens Sip Mima guint Sena aneat cones” | at ogseath| Cateye an sesegi omer tate oo ws cose SRSA ema etree oe despre gegnuninbe Be ee ae He name ono stm Sng Pays Sm amet Renae a ‘vec sew tr Bsxaersoiee semen foes soe fl aeCQl-27 Special Pracess: Casting System Assessment ‘Wein 1, eva 102015, ‘PROGESS TABLEA- Duele on pater tn ann tener nto yma enc a anu etre ure Fe age UH Ren noe epe ‘Oberst Camm | Pama: tram | cregeyProcens simp ‘bau: Acum Consmom | Nat Agee =e fey | Servis yy Seertnaran tres etetrurgte aru ee 0 eo ss | Maecientn ener ererestes rss a senaingraaererees 894 ret ee ‘Sabeereeuanwatre eveand ec ay ctuinrasew bere tnacaQL27 Special Process: Casting System Assessment tesuen TOO [emrraeaienresmemroaectsr ss rer ae earn he ms nt Met frat ow epremowey te aah) Tri henay? Aspte pods te? pcp anter? amr? tex | CarsnoryPmcees step ‘Steervations‘Gomeonis | Pama Fai | ‘See can! Conaon” | Not Appi i Sa = oe LEE ene 2 | anc aint enero meee 7) le SScal-27 Spact Pocs Cacng Stan Aataamint AIAG ines The etapa Cos Parrarce” PROGESS TABLEA: fuctielos femeseceen erry erento eye eee ene ys matey ene mee aegis penta ig apa [Fret antennae rome ier ari a whan [ane nape cary Bt] Torry andy? A me AI Aapwct pr manBart Cer [Deete the eget [ ces uensenciecetsasmereeatione mere | Rreetm were worm rimCQl-27 Special Process: Gasting System Assessment [cin cas corey bm a These anc Apwaicpeaue lin? Aust manee? meh lesen ep ‘mon | eategeryPveceas Step ‘tna Restamart arn ie Tevares este onary Oey ali e-ey aed pt “a Sie PSR eT ns vet aisShi rts sey spans AIAG ‘Mersin 1, eevee 1022015 he ntalya rn: Pr PROCESS TARLEA- Ductielron [per tacebv nie eaten [eben nicereus ve ha Snseenieanrg meester cater [ae sony eve is aT] Tewe ana? Awe pada? Aeoee et nunter? 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Ow te one atom [cmgnracee se a [Seer cae Tr aT fog ath manage owe mee | es eae nae ntcors eon —aeereeeerees omcni Beene eemeermoneey Sera eememeenais ee nen terete as srant un eure antares ness ar ter | “Weeten teenyProcess: ‘Wein 1, tue 30015, i uta Sect recess Cong Syaton sessment AIAG PROCESS TABLE C: CENTRIFUGAL LINERS. [ata ave eapecoend erm He wity loot? Aepclogad int Awetcinree? Om ‘Ginerratacs: Eomense | Paes all tem | GatepenPrcen Sep bout ictolGonainon | ot plea Tara raat errs ie a SSAIAG 2m Speci Proces: Casting Sytem Arecemet The Catt ft arn” ‘Version I, sebed 1001S PROCESS TABLES Gentian! Lnnss cae eee Pe a a Fee ene earch [esas pe rdiyDmBt Tr eta? Rea pontir Aapeseet et Ort Eewertronrtrma | ie Gamma | es Fal) Sent boxiealestamed [Se Se tt ee =] baer eam ic mresreeeeermecet )| a Ee Senna ae ts net nae Fimeanutarurs rartra oyomesce ne maemges ry we | eames Recreate ecm aaa 2 | ite Ee arcane rome Ea =| ae26. 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