AIAG 2m cava Special Process: Coating System Assessment ‘The cata or peak porornance Version 2. Issued: 02/2012 ABOUT AIAG Purpose Statement Founded in 1982, AIAG is a globally recognized organization where OEMs and suppliers unite to address and resolve issues affecting the worldwide automotive supply chain. AIG's goals are to reduce cost and complexity through collaboration; improve product quality, health, safety and the environment; and optimize speed to market throughout the supply chain AIAG Organization AIAG is made up of a board of directors, an executive director, executives on loan from member companies, associate directors, a full-time staff, and volunteers serving on project teams. Directors, department managers, and program managers plan, direct and coordinate the association's activities under the direction of the executive director. AIAG Projects Volunteer committees focus on business processes or supporting technologies and methodologies. They ‘conduct research and develop, publish, and provide training on standards, conventions, standard business practices, white papers, and guidelines in the areas of automatic identification, CAD/CAM, ED\electronic commerce, continuous quality improvernent, health focus, materials and project ‘management, occupational health & safety, returnable containers and packaging systems, ‘ransportation/customs and truck & heavy equipment. ‘AIAG PUBLICATIONS ‘An AIAG publication reflects @ consensus of those substantially concerned with its scope and provisions. An ‘AIAG publication is intended as a guide to aid the manufacturer, the consumer, and the public. The existence of ‘an AIAG publication does net in any respect preclude anyone from manufacturing, marketing, purchasing, or Using products, processes, or procedures not conforming tothe publication. CAUTIONARY NOTICE AIAG publications are subject to periodic review and users are cautioned to obtain the latest editions. MAINTENANCE PROCEDURE Recognizing that this AIAG publication may not cover al circumstances, AIAG has established @ maintenance procedure. Please refer to the Maintenance Request Farm af tho back of this document to submit a request Published by: Automotive Industry Action Group 126200 Lahser Road, Suite 200 ‘Southfield, Michigan 48033 Phone: (248) 258-3570 + Fax: (248) 358-3253 APPROVAL STATUS The AIAG Quality Steering Committee and designated stakeholders approved this document for publication on Fobruary 7, 2012 AIAG COPYRIGHT AND TRADEMARK NOTICE: (© 2012 Automotive Industry Action Group, excopt that copyright s nat claimed asf any port ofan eriginal work prepared by a US. oF state goverment oficer or employee as pat ofthe person's fea dues EExcapt as noted above, al ghts ar reserved by AIAG and ro pat of hese materials may be reproduce. eorted, stored in a retivalsystom, or transmit, m any frm or by any means, electronic. photocopying, recaring, oF etherwse, witout the prior writen pormission of AutomotveIndusty ‘Acton Group. Copyright infringement 8 violation of federal law sutyect a chm and cv penaies. [AIAG and Automotive Industry Acton Group are registred sevice marks of he Autometie Industry Acton Group, Automotive industry Action Group ‘makes no claim fo any rademark a @ hs par. Trademarks of hd pares inuded in these mater are the property 0! respective one's (©2012 Automotive Industry Action Group ISBN: 978-1-60534-245-0-90000caxtz AIAG 2» Special Process: Coating System Assessment Version 2, Issued: 02/2012 ‘The cata for peak performance CHANGES TO CQI-12 2" EDITION The Special Process: Coating System Assessment, 2™ edition contains some new requirements, changed requirements and clarifications that the supplier organization will need to consider in making its self- assessment. This 2” edition is a collaborative work of OEM, Tier | suppliers, and coating suppliers. Below is a summary of the important changes in this 2” edition. L New Process Tables have been added: © PTJ: Anodizing + PTL: Part Inspection and Testing 2. Process Tables have been renamed: * Table C: Conversion Coatings (Phosphate, Non-phosphate, Chromate, Non-chrome) * Table E: Spray * Table H: Autodeposition © Table I: Cure Equipment has been moved to Process Table K. 4. The format and layout of the Process Tables have been improved to facilitate the coating system assessment 5. The following sections contain the most significant updates or changes: * Section 1: Special Process: Coating Process Assessment (General Facility Overview) © Question 1.8: Does the coater collect and analyze data over time, and react to this data? Are records available? The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time. Methods of analysis shall include ongoing trend or historical data analysis of special product or process parameters. The organization shall determine which parameters to include in such analysis. All process control and testing records must be retained for a minimum of one calendar year after the year in which they were created. * Section 2: Floor and Material Handling Responsibility © Question 2.15: Lighting of Inspection Area © Question 2.16: Are the water rinse control plans up to date and reflect best case practices? + Process Tables A, B, C, D, E, F, G, H, 1, and J: have expanded the Category/Process Steps along with changes in the “Monitoring Frequency” column. © Process Table K: Equipment has updates to columns: “EQUIPMENT TYPE;” “Verification Frequency,” and “Calibration / Certification Frequency.”AIAG2a cal-12 Special Process: Coating System Assessment The catayt for pak pertormanco Version 2. Issued: 02/2012 FOREWORD Automotive Industry Action Group (AIAG) committees are made up of volunteers from member companies in the automotive industry. The work of preparing process audits is done by AIAG techn committees, al The main task of technical committees is to prepare Automotive Standards and System Requirements, Draft documents adopted by the technical committees are circulated to the Steering Committee for review and consensus approval. Publication of the documents requires approval by the Quality Steering Committee. ‘The Quality Steering Committee would like to acknowledge and thank the following individuals and their companies who have contributed time and effort to the development of this document. Acknowledgements Jim Aide Acadian Group Brian Glowacki Atotech USA, Inc. Jeff Szotek Chrysler Group LLC Kimberly Tress Chrysler Group LLC Murli Prasad Dipsol of America, Inc. Albert Gelles Doerken Corporation Larry Xu Ford Motor Company Steven Kwong General Motors Company Ron Doran Henkel Technologi Elizabeth Hanna Howard Finishing, LLC Jamie Brooks Magni Industries Craig Barboza Modem Plating Corporation Harish Bhatt Metalast International, Inc. Karen Whitmore AIAGcaut2 AIAG» Special Process: Coating System Assessment Version 2, Issued: 02/2012 The catayst for peak performance TABLE OF CONTENTS ABOUT AIAG FOREWORD ACKNOWLEDGEMENTS. ‘TABLE OF CONTENTS. Genenat PROCESS APPROACH, COATING SYSTEM ASSESSMENT GOALS... ASSESSMENT PROCESS. ‘ASSESSOR QUALIFICATIONS. Omer REQUIRENENTS. 1 cori 1.1 Generat 1.2 APPLICATION. 2 THE COATING SYSTEM ASSESSMENT PROCEDURE. © VN N anne eww 3 SPECIAL PROCESS: COATING ASSESSMENT. ‘APPENDIX A ~ PROCESS TABLES. GLOSSARY ssnAIAG car-t2 Special Process: Coating System Assessment The catalyst or peak performance Version 2, Issued: 02/2012 INTRODUCTION General The work of preparing Special Process: Coating System Assessment (CSA), Second Edition, was carried out through the AIAG Coating Work Group. These coating requirements are complementary to customer and product standards, The CSA can be used to assess an organization's ability to meet the requirements in this assessment, as well as customer, regulatory, and the organization's own requirements. The CSA can also be used between an organization and its suppliers. In the CSA, the word “shall” indicates a requirement for purposes of the self assessment. Failure to meet the requirements results in an assessment that is either “Not Satisfactory” or “Needs Immediate Action”, The word “should” indicates a recommendation. Where the term “such as” is used, any suggestions given are for guidance only. Process Approach The CSA supports the automotive process approach as described in ISO/TS 16949. Coating System Assessment Goals The goal of the CSA is the development of a coating management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain. The CSA, coupled with an internationally recognized quality management system and applicable customer-specific requirements, defines the fundamental requirements for coating management systems. ‘The CSA is intended to provide a common approach to a coating management system for automotive production and service part organizations, Assessment Process ‘Ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to reexamine the continuing compliance with the CSA. Each assessment shall include a review of the organization's systems using the CSA. Successive Job Audits (Section 3.0 of this document) shall parts from different automotive component manufacturers that require complian: ample to the CSA document The assessment shall use the process approach to auditing/assessing as identified by the requirements of ISO/TS 16949. Assessor Qualifications Assessor(s) shall have the following specific experience to conduct the COATING SYSTEM ASSESSMENT:canta AIAG Special Process: Coating System Assessment Version 2, Issued: 02/2012 The catalyst for peak performance 1. Bean experienced quality management system (QMS) internal auditor (for example, ISO/TS 16949, ISO 9001) 2. Assessor shall possess coating knowledge. Evidence shall include a minimum of 5 years of experience in coating or a combination of formal chemical education and coating experience totaling a minimum of 5 years. 3. Assessor shall possess knowledge of and be familiar with the application of automotive quality core tools including statistical process control, measurement systems analysis, part approval, failure mode and effects analysis, and advanced quality planning. Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in #1 Other Requirements ‘The organization shall keep records as evidence of compliance to the requirements identified in the CSA, as well as 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.AIAG a cav2 Special Process: Coating System Assessment The cates for peak perfomance Version 2, issued: 02/2012 1 SCOPE 1.1 General This document specifies process requirements for an organi tion or its suppliers performing applicable coating, who need to: © demonstrate ability to consistently provide product that meets customer and applicable regulatory requirements, and ‘© enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system. ‘The Coating System Assessment is applicable to sites where customer and/or service are processed throughout the automotive supply chain. parts for production 1.2 Application All requirements of the CSA are generic and are intended to be applicable to all organizations performing the coating operations addressed in this document, regardless of type, size, and product. Twelve Process Tables have been developed and the appropriate table(s) is to be referenced during the assessment, The Process Tables are specific to Coating processes as noted below: ‘+ Process Table A — Pretreatment (Aqueous) © Process Table B — Pretreatment (Mechanical) '* Process Table C ~ Conversion Coatings (Phosphate, Non-phosphate, Chromate, Non- chrome) * Process Table D ~ Powder © Process Table Spray ~ Blectrocoat + Process Table * Process Table G — Dip/Spin ‘© Process Table H — Autodeposition Process Table 1 ~ Cure * Process Table J - Anodizing and Hard Coat Anodizing Process Table K ~ Equipment ‘Process Table L ~ Part Inspection and Testing, These Process Tables contain requirements for: 1. Process and Test Equipment 2. Process Monitor Frequencies 3. In-Process/Final Test FrequenciescaQl-12 Special Process: Coating System Assessment Version 2. issued: 02/2012 4. Test Frequencies The Process Tables specify the tolerances of process paramete control parameters and parts. The Requirements and C when to refer to the Process Tables. and the frequencies for checking proces lance in the CSA form will notify the assessorAIAG 2 caut2 Special Process: Coating System Assessment ‘The cata for peak performance Version 2, Issued: 02/2012 2 THE COATING SYSTEM ASSESSMENT PROCEDURE 6, Obtain current copy of CQI-12 Special Process: Coating System Assessment, 2™ edition from AIAG. Identify all coating processes to which CQI-12 Special Process: Coating System Assessment, edition applies (see CQI-12, 1.2). Record these processes on the CSA. ‘Complete the CSA, determining the level of compliance. A minimum of one job audit (Section 3) shall be performed during each assessment. ‘Address each “Not Satisfactory” item and determine corrective action, including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. “Needs Immediate Action” requires immediate containment of suspect product. Address each “Needs Immediate Action” item and determine corrective action(s), including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. “Number of Process Table items identified as failed in Comments/Observation column” to be reported, Assessments shall be conducted annually.caQl-12 Special Process: Coating System Assessment Version 2, issued: 02/2012 3 SPECIAL PROCESS: COATING ASSESSMENT INSTRUCTIONS FOR COMPLETING THE COVER SHEET. B COVER PAGE wenn INSTRUCTIONS FOR COMPLETING SECTIONS 1 AND CCoarine SysTEMs ASSESSMENT: SECTION 1-MANAGEMENT RESPONSIBILITY AND QUALITY PLANNING. 15 id COATING SySTEMS ASSESSMENT: SECTION 2- FLOOR AND MATERIAL HANDLING RESPONSIBILITY. INSTRUCTIONS FOR COMPLETING THE JOB AUDIT. aiaT JOB AUDIT... 10AIAG a canta Special Process: Coating System Assessment The cata for peak performance Version 2, Issued: 02/2012 Instructions for completing the Cover Sheet 12, Facility Name: Name of the facility being assessed. One form shall be used for each facility The facility may have several buildings or physical locations in the same general area. If there is a separate management team (Quality Manager and Metallurgist) or different management system, then these locations shall be considered as separate facilities Address: The street address of the facility being assessed; P.O. Box numbers may be given as additional information. Phone Number: The phone number of the facility. If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used. Fax Number: The fax number of the facility. Number of Coating Employees at this Facility: The number of employees, salaried and hourly, associated with the coating operation at this facility Captive Coater (Y/N): Enter “Y” if this facility coats components for their own company. Enter “N” if the company does not coat any components for their own company. ‘Commercial Coater (Y/N): Enter “Y” if this facility coats components for companies other than their own company. Enter “N” if this facility does not coat any components for other companies Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be used to avoid confusion with different numeric formats. Example: May 3 — 4, 2012. Date of Previous Assessment: List the date of the previous Special Process: Coating System Assessment of this facility. Date of Re-assessment (if necessary): If “Not Satisfactory” findings were observed from the original assessment, then the coater shall address each item and determine correct action, including root cause analysis and implementation of the corresponding corrective action(s). The date of the re-assessment shall be given here, and the appropriate Question(s) from Sections 1 in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. In addition, the “Number of Not Satisfactory Findings” shall be modified as appropriate. 3 ‘Type(s) of Coating at this Facility: Place a checkmark to designate all coating process(es) performed at this facility. This information determines the appropriate Process Table that shall be used during the assessment. Processes not listed on the cover sheet are not part of the Coating ‘System Assessment. Current Quality Certification(s): The coater shall list their current quality certifications, e.g., ISO/TS 16949, ISO 9001. Certifications may be from 3rd party sources or customer quality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given. Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available, of the principal participants from the coater’s organization. Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), if available, of the auditor(s). Number of “Not Satisfactory” Findings: Enter the number of “Not Satisfactory” findings observed during the assessment.caQl-12 Special Process: Coating System Assessment Version 2 Issued 02/2012 16. Number of “Needs Immediate Action” Findings: Enter the number of “Needs Immediate Action” findings observed during the assessment. Number of “Fail” Findings in the Job Audit(s): from the job audit. ter the number of “Fail” findings observed Number of Process Table items identified as failed in Comments/Observation column: Enter the number of failed findings observed in the completed process tables.AIAG The catast or peak partormarce COVER PAGE cal-12 Special Process: Coating System Assessment Version 2, Issued: 02/2012 [Special Process: Coating System Assessment 2nd Edition Foci Nanas [adsense Phone Number Fax Norber Number ot Coating Erpioyees ats Fach Cape Comer {Commercial Coster (7 Dae of Assasement Daa o Previous Rasosanent [Curent uaiy Carineanony [ate of Re-accnsarent (I necessary [Personnel Contes [rare amber of Wat Satatacony Fa umber of Needs mediate Raton Fi Number of Far Figs athe Job ADAMS) [Humbe of Process Table Rema nol necting Minimum Ri of Coating Processes at this Fac [Process Table A DPrevestmert, AqueDvs [Process Table B [Preveatment Mechanical [conversion Coat [Process Table D [Power Coat [Process Table © [Process Table F Elecrocost [process Table. Si [Process Table H [astose Process Table! cure. Process TabieT [anode semeat ess Table PartincaQl-12 Special Process: Coating System Assessment Version 2, Issued: 02/2012 The catalyst for peak performance Instructions for completing Sections 1 and 2 Sections 1 - 2 contain questions and the requirements and guidance for each question. The Sections are: ‘The assessor shall assess the coater’s compliance to Sec Section 1 - Management Responsibility & Quality Planning Section 2 ~ Floor and Material Handling Responsibility ns | and 2 by comparing the evidence presented by the coater to the requirements listed in the “Requirements and Guidance” column. 14 NOTE 1 NOTE 2; NOTE 3: NOTE 4: In the “Requirements and Guidance” column, the word “shall” indicates a requirement and the term “such as” indicates that any suggestions given are for guidance only. ‘The “Requirements and Guidance” column will indicate to the assessor when the Process Tables are pertinent to the Questions. When the Process Tables are pertinent to the Question, the assessor shall assess the coater’s compliance to the specified section(s) in the Process Tables. If the question is not applicable to the coater, then the assessor shall place a checkmark in the “N/A” Assessment column. If the observed evidence is in compliance to the question, the assessor shall note the evidence in the “Objective Evidence” column and place a check mark in the “Satisfactory” column. If the observed evidence is not in complian to the question, then the assessor shall note the non-compliance in the “Objective Evidence” column and place a check mark in the “Not Satisfactory” column. Where nonconforming product is identified in the assessment of a given question the assessor shall place a check mark in the “Needs Immediate Action” (NIA) column. 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