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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. AIAG's goals are to reduce cost and

complexity through collaboration; improve product quality, hea lth, 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,

EDI/electronic

commerce,

continuous

quality

improvement,

health

focus,

materials

and

project

management,

occupational

health

&

safety,

returnable

containers

and

packaging

systems,

transportation/customs and truck & heavy equipment.

AIAG PUBLICATIONS

An AIAG publication reflect a consensus of those substantially concerned with its cope and provisions. An AIAG publication is intended as a guide to aid the manufacturer, the consumer and the general public. The existence of an AIAG publication does not in any respect preclude any one from manufacturing, marketing purchasing or using products, processes, or procedures not conforming to the publication.

CAUTIONARY NOTICE

AIAG publications are subject to periodic review and users are cautioned to obtain the latest editions.

MAINTENANCE ROCEDURE

Recognizing that this AIAG publication may not cover all circumstances, AIAG has established a maintenance procedure. Please refer to the Maintenance Request Form at the back of this document to submit a request.

Published by:

Automotive Industry Action Group

2 6 2 0 0 L a h s e r R o a d , S u i t e 2 0 0

S o u t h f i e l d , M i c h i g a n 4 8 0 33

Phone: (248) 358-3570 • Fax: (248) 358-3253

APPROVAL STATUS

The AIAG Quality Steering Committee and designated stakeholders approved this document for publication on August 1, 2007.

AIAG COPYRIGHT AND TRADEMARK NOTICE:

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated.

Copyright is not claimed as to any part of an original work prepared by a U.S. or state government officer or employee as part of the person's official duties. Al rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.

(3)

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 technical

committees.

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.

(4)

ACKNOWLEDGEMENTS

Core Members:

Pete Batche — Robert Bosch LLC

Mel Dilley — DaimlerChrysler Corp.

Curt Holmes — Commercial Steel Treating Corp.

Ed Jamieson — Bodycote Thermal Processing

Young Kim — Ford Motor Company

Brett Lenhausen — General Motors Corporation

Philip Mikula — TRW Automotive, Inc.

Murli Prasad — General Motors Corporation

Supporting Members:

Todd Bensinger — DaimlerChrysler Corp.

Scott Brodersen — DaimlerChrysler Corp

Dave Calkins — DaimlerChrysler Corp

Leonard Gadzinski — Acument Global Technologies North America

Tim Green — BSI Americas, Inc.

Dave Hernacki — Commercial Steel Treating, Corp.

Dean Higdon — Acument Global Technologies North America

Jef f Martin — ZF Fr ied richshaf en , AG

Mik e Oberg — Induction Services, Inc.

Mike Wiezbowski — DaimlerChrysler Corp.

(5)

TABLE OF CONTENTS

ABOUT AIAG ... 1

FORWORD ... 3

ACKNOWLWDGEMENTS... 4

INTRODUCTION... 6

1 SCOPE... 8

1.1 GENERAL... 8

1.2 APPLICATION... 8

1.3 REFERENCE... 9

2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE ... 10

3 SPECIAL PROCESS: HEAT TREAT SYSTEM ASSESSMENT PROCEDURE ... 11

INSTRUCTIONS FOR COMPLETING THE COVER SHEET... 12

SPECIAL PROCESS: HEAT TREAT ASSESSMENT FORMS... 18

INSTRUCTIONS FOR COMPLETING THE JOB AUDIT ... 37

JOB AUDIT FORM ... 38

APPENDIX A — PROCESS TABLES ...42

APPENDIX B — GLOSSARY... 66

(6)

INTRODUCTION

General

The work of preparing CQI 9: Special Process: Heat Treat System Assessment (HTSA), Second Edition,

was carried out through the AIAG Heat Treat Work Group. These heat treat requirements are

complementary to customer and product standards.

The HTSA 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 HTSA can also be used

between an organization and its suppliers.

In the HTSA, 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 HTSA supports the automotive process approach as described in ISO/TS16949:2002.

Heat Treat System Assessment Goals

The goal of the HTSA is the development of a heat treat management system that provides for continual

improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain.

The HTSA, coupled with an internationally recognized quality management system

and applicable

customer-specific requirements, defines the fundamental requirements for heat treat management systems.

The HTSA is intended to provide a common approach to a heat treat management system for automotive

production and service part organizations.

Assessment Process

Ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to

re-examine the continuing compliance with the HTSA. Each assessment shall include a review of the

organization's systems using the HTSA. Successive Job Audits (Section 4.0 of this document) shall

sample parts from different automotive component manufacturers that require compliance to the HTSA

document.

The assessment shall use the process approach to auditing as identified by the requirements of ISO/TS

16949:2002.

(7)

Assessor Qualifications

Assessors(s)

shall have the following specific experience to conduct the HEAT TREAT SYSTEM

ASSESSMENT:

1.

Be an experienced quality management system (QMS) internal auditor (for example,

ISO/TS 16949:2002, ISO 9001:2000)

2.

Assessor shall possess heat treating knowledge. Evidence shall include a minimum of 5

years experience in heat treating or a combination of formal metallurgical education and

heat treating experience totalling 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, measurements system 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 item #1.

Other Requirements

The organization shall keep records as evidence of compliance to the requirements identified in the

HTSA, as well as 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.

(8)

1 S CO P E

1.1 General

This document specifies process requirements for an organization or its suppliers performing applicable

heat treating, 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 Heat Treat System Assessment is applicable to sites where customer-specified parts for production

and/or service are processed throughout the automotive supply chain.

1.2 Application

All requirements of the HTSA are generic and are intended to be applicable to all organizations

performing the heat treat operations addressed in this document, regardless of type, size, and product.

Note: Process Table E is only applicable to process affecting the final characteristics of the part.

Five Process Tables have been developed and the appropriate table(s) is to be referenced during the

assessment. The Process Tables are specific to heat treat processes as noted below:

Process Table A – Ferrous

Carburizing

Carbonitriding

Carbon Restoration or Correction

Neutral Hardening (Quench and Temper)

Austempering

Martempering

Tempering

Precipitation Hardening – Aging

Process Table B – Ferrous

Nitriding (Gas)

Ferritic Nitrocarburizing (Gas or Salt)

Process Table C – Aluminum Heat Treating

Process Table D – Induction Heat Treating – Ferrous

Process Table E – Annealing, Normalizing, and Stress Relieving

Conformance to CQI-9 is required for all organization that perform annealing,

normalizing, or stress-relieving to achieve desired final characteristics of the part.

(9)

Note:

Material producers of primary or raw materials, or any intermediate thermal treating

process step(s) that do not affect the final characteristics of the part are exempt from

conforming to the requirements in CQI-9.

These Process Tables contain requirements for:

1.

Process and Test Equipment

2.

Pyrometry

3.

Process Monitor Frequencies

4.

In-Process /Final Test Frequencies

5.

Quenchant and Solution Test Frequencies

The Process Tables specify the tolerances of process parameters and the frequencies for checking process

control parameters and parts. The Requirements/Guidelines in the HTSA form will notify the assessor

when to refer to the Process Tables.

1.3 Reference

The following standards are referenced in this document. The applicability is limited to the subject matter

referenced.

Standard Number

Title

Standard’s Organization

AMS 2750D

Pyrometry

SAE Aerospace

www.sae.org

SAE J415

Definition of the Heat Treating

Terms

SAE International

www.sae.org

SAE J864

Suface Hardness Testing With

Files

SAE International

www.sae.org

(10)

2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE

1.

Obtain current copy of CQI-9 Special Process: Heat Treat System Assessment, 2nd edition

from AIAG.

2.

Identify

all

heat

treat

processes

to

which

CQI-9

Special

Process:

Heat

Treat

System

Assessment 2nd edition applies (see CQI-9, 1.2). Record these processes on the HTSA, Page 1.

3.

Complete the

HTSA,

determining

the

level

of

compliance. A minimum

of

one job

audit

(Section 4) shall be performed during each assessment.

4.

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.

5.

“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.

(11)

3 SPECIAL PROCESS: HEAT TREAT ASSESSMENT

INSTRUCTION FOR COMPLETING THE COVER SHEET...12

COVER SHEET FORM...14

INSTRUCTIONS FOR COMPLETING SECTION 1-3 ...15

SECTION 1: MANAGEMENT RESPONSIBILITY & QUALITY PLANNING ...18

SECTION 2: FLOOR AND MATERIAL HANDLING RESPONSIBILITY ...25

SECTION 3: EQUIPMENT ...31

INSTRUCTIONS FOR COMPLETING THE JOB AUDIT ...37

(12)

Instructions for completing the Cover Sheet

1.

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.

2.

Address: The street address of the facility being assessed; P.O Box numbers may be given as additional

information.

3.

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.

4.

Fax Number: The fax number of the facility.

5.

Number of Heat Treat Employees at this Facility: The number of employees, salaried and hourly, associated with

the heat treat operation at this facility.

6.

Captive Heat Treater (Y/N): Enter "Y" if this facility heat treats components for their own company. Enter "N" if the

company does not heat treat any components for their own company.

7.

Commercial Heat Treater (Y/N): Enter "Y" if this facility heat treats components for companies other than their own

company. Enter "N" if this facility does not heat treat any components for other companies.

8.

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, 2006

9.

Date of Previous Assessment: List the date of the previous CQI-9 Special Process: Heat Treat System Assessment

of this facility.

10.

Type(s) of Thermal Processing at this Facility: Place a checkmark to designate all thermal 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 Heat Treat System Assessment.

11.

Current Quality Certification(s): The heat treater shall list their current quality certifications, e.g., ISO/TS

16949:2002, ISO 9000:2002. 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.

12.

Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment,

then the heat treater 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 – 4, 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 Not Satisfactory Findings" shall be modified as appropriate.

13.

Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available,

of the principal participants from the heat treater's organization.

(13)

14.

Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), if available, of the

auditor/assessor(s).

15.

Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findings observed during the

assessment.

16.

Number of “Needs Immediate Action” Findings: Enter the number of “Needs Immediate Action” finding observed

during the assessment.

(14)

Special Process: Heat Treat Process Assessment

Facility Name:

Address

Phone Number

Type(s) of Thermal Processing at this Facility:

Fax Number

Process Table A – Ferrous

Carburizing

Number of Heat Treat Employees at this Facility:

Carbonitriding

Carbon Correction

Captive Heat Treater (Y/N)

Neutral Hardening

Quench & Temper

Commercial Heat Treater (Y/N)

Austempering / Martempering

Tempering

Date of Evaluation:

Precipitation Hardening /Aging

Date of Previous Evaluation:

Process Table B - Ferrous

Nitriding (Gas)

FerriticNitrocarburizing (Gas or

Salt)

Process Table C - Aluminum

Aluminum Heat Treatment

Process Table D - Ferrous

Induction Heat Treating

Process Table E

Annealing

Normalizing

Stress-Relleving

Current Quality Certification(s)

Date of Re-assessment: (if necessary):

Personnel Contacted:

Name:

Title:

Phone:

Email:

Auditors/Assesors:

Name:

Company:

Phone:

Email:

Number of “Not Satisfactory” Findings:

Number of “Needs Immediate Action” Findings:

Number of “Fall” Findings in the Job Audits:

(15)

Instructions for completing Sections 1 - 3

Sections 1 - 3 contain questions and the requirements/guidance for each question. The Sections are:

Section 1 – Management Responsibility & Quality Planning

Section 2 – Floor and Material Handling Responsibility

Section 3 – Equipment

The assessor shall assess the heat treater's compliance to Sections 1 – 3 by comparing the evidence

presented by the heat treater to the requirements listed in the "Requirements and Guidance" column.

NOTE 1:

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.

NOTE 2:

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 heat treater's compliance to the specified section(s) in the Process

Tables.

NOTE 3:

If the question is not applicable to the heat treater, 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 compliance

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.

NOTE 4:

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. NIA requires immediate containment of suspect

product.

(16)

General Notes for AMS 2750D

AMS 2750D is referenced in the Pyrometry Section (Section 2.0) of the Process Tables. Organizations

and suppliers shall comply with the sections of AMS 2750D that reference thermocouples, the calibration

of thermocouples and instrumentation, and the procedure for conducing furnace temperature uniformity

surveys (TUS) see below.

Exceptions to this requirement are listed below in the respective sections.

Thermocouples and Instrumentation

Section 3.1 – Temperature Sensors (Therm ocouples)

Section 3.2 –Instrumentation –Note: Frequency reductions per AMS 2750D are

not allowed by CQI-9

Exceptions (Compliance to the following sections are not required by CQI-9)

Section Number

Explanation

3.2.5.1 & 2

Temperature

controlling

instruments

purchased

prior

to

1

year

after

le

release

of

AMS

2750D

are

exempt

of

3.2.5.1 and 3.2.5.2.

3.2.5.3.1

One point sensor input is acceptable.

3.2.5.5

Sensitivity checks during calibration

are not required.

System Accuracy Test (SAT) Procedure (Section 3.4)

SAT shall be performed by one of the two methods listed below.

CQI-9 requires either a (1) comparative check of the control temperature sensor

(CTS) to a calibrated test temperature sensor (CTTS) or (2) resident thermocouple

(R-T/C), per AMS 2750D.

(1) The CTS shall be +/- 5C (or 4:- 10F) of the CTTS at a typical operating

temperature range; this check shall be performed monthly. The procedure

shall follow AMS 2750D Section 3.4.

(2) The

relationship

between

the

CTS

and

R-T/C

at

the

operating

temperature range shall be within +/- 1C (or +/- 2F) of their relationship

determined at the time of the most recent temperature uniformity survey: this

check shall be performed weekly. SAT per AMS 2750D Section 3.4 is not

required with this method.

Any actions to correct a failing reading or validate a test result shall be

documented

Type K and N thermocouples shall be checked monthly for equipment operating

at or above 760C (1400F) and changed annually at a minimum.

Type K and N thermocouples shall be checked quarterly for equipment operating

below 760C (1400F) and changed every two years at a minimum.

Type R and S thermocouples shall be checked monthly for equipment operating at

or above 7600 (1400F) and changed every two years at a minimum.

Furnace Temperature Uniformity Survey (TUS)

Section 3.5.2 – Multiple Qualified Operating Temperature Ranges

Section 3.5.3 – furnace Modifications

(17)

Section 3.5.5 – Initial TUS

 Minimum and maximum temperature ranges shall be tested per

AMS 2750D. Exception: If the operating range of the Qualified

Work Zone is equal to or less than 85C (153F) then only one

temperature is required to be tested. The temperature shall be

within the operating range of the Qualified Work Zone.

Section 3.5.6 – Periodic TUS (For CQI-9. a minimum of once per year periodic

TUS is required)

 Minimum and maximum temperature ranges shall be tested per

AMS 2750D. Exception: If the operating range of the Qualified

Work Zone is equal to or less that 35C (153F) then only one

temperature is required to be tested. The temperature shall be

within the operating range of the Qualified Work Zone.

Section 3.5.8 - Furnace Parameters During TUS

Section 3.5.9 - Furnace Temperature at Insertion of TUS Sensors

(Thermocouples)

Section 3.5.10 - Load Condition

Section 3.5.11 - Furnace Atmosphere During TUS

Section 3.5.13 - Batch Furnaces, Salt Baths. Controlled Temperature Liquid

Baths, and Fluidized Bed Furnaces EXCEPT:

 3.5.13.3.2: CQI-9 requires that data from the TUS sensors is

automatically recorded.

Section 3.5.14 - Continuous and Semi-Continuous Furnaces

Section 3.5.15 - Alternative Testing Methods for Continuous and

Semi-Continuous Furnaces or Furnaces with Retorts or Muffles

Section 3.5.16 - Temperature Uniformity Survey Sensor Failures

Section 3.5.18- Relocatton of Hot or Cold Recording Sensors for Class A or C

Instrumentation

Section 3.5.20 - Temperature Uniformity Survey instrumentation

Section 3.5.21 - Temperature Uniformity Survey Report

(18)

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T h e o rg a n iz a tio n s h al l in c or p o ra te th e u s e of a d o cu m e n te d C on tr ol P la n p ro c e du re a n d e n su re th e C o n tr o lP la n s a re u p da te d to re fl ec t cu rr e n t c on tr ol s. T h e C o n tr o l P la n s s ha ll b e w ri tt e n fo r e a ch p a rt o r p a rt fa m ily o r th e y m a y b e pr o ce s s-s p e ci fic a nd w ri tt e n fo r e ac h p ro ce s s. In a n y c a se , th e y s h al l a d d re ss a ll p ro ce s s s te ps fr o m p a rt re c e ip t to p ar t s hi p m e n ta n d id e n ti fy a ll e q u ip m e n t u se d a n d a ll k ey h e a tt re at p ro c e ss p a ra m e te rs a s d ef in e d by th e o rg a n iz a tio n . A cr o s s-fu nc tio n a l te a m , in cl ud in g a pr o du c tio n o p e ra to r, sh a ll b e u se d in th e d e v el o p m e nt o f C o n tr o lP la n s, w h ic h sh a ll b e co n s is te n tw it h a ll a ss o ci a te d do c u m en ta ti o n s u ch a s w o rk in st ru c tio n s, s h o p tr a ve le rs , a n d P F M E A s .A ll S p ec ia l c ha ra c te ri st ic s , a s d e fin e d b y th e o rg a n iz a tio n a n d its c u st o m e rs , s h a ll b e id e n tif ie d , d e fin e d , an d a d d re ss e d in th e C o nt ro l P la n s. S a m p le s iz e s a nd fr e q u e nc ie s fo r e va lu a tio n o f p ro c e ss an d p ro d u c tc h a ra ct e ri s tic s s h al la ls o b e a d d re ss e d co n si st en t w it h th e m in im u m re q u ir e m e nt s lis te d in th e P ro c e ss T a bl e s, S e ct io ns 3 .0 an d 4 .0 .

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A re h e a t tr e a t p ro ce s s c o nt ro l an d d a te to u p p la ns re fle c tin g c u rr e n t p ro ce s si n g ?

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T o e n s u re a ll cu s to m e r re q ui re m e n ts a re b o th u n d e rs to o d a n d sa ti sf ie d ,t h e o rg a n iz a ti on s h al l h a v e a ll re la te d h ea t tr ea t a n d cu s to m e r re fe re n ce d s ta n da rd s a n d sp e ci fic a tio n s av a ila b le fo r u s e an d a m e th o d to e n s ur e th a t th e y a re c u rr e n t. S u ch s ta n da rd s a n d sp e ci fic a tio n s in cl u d e , b ut a re n o t lim it e d to , th o se re le va n t d o cu m e n ts p u b lis he d b y S A E , A IA G , A S T M , G e ne ra l M o to rs , F o rd , an d D a im le rC hr ys le r. T h e o rg a n iz a ti o n s h a ll h av e a p ro c e ss to en s u re th e ti m e ly re vi e w , d is tr ib u ti o n , a n d im p le m e n ta ti on o f a ll re le va n t cu s to m e r a nd in d us tr y e n gi n e e ri ng s ta nd a rd s s pe c ifi ca ti o n s a n d C h a n g e s b a s ed o n c os tu m er -r e q u ir e d sc h e du le . T im e ly re vi ew s ho u ld b e a s s o o n a s p os si b le a n d s h a ll n ot e x ce e d tw o w o rk in g w e e ks .T h e o rg a n iz a ti o n s h a ll d oc u m e nt th is p ro c e ss o f re vi e w a n d im p le m e n ta ti on , a n d it s h a ll a dd re ss ho w c u st o m e r a n d in d u st ry d o cu m e n ts a re o b ta in e d , h o w th e y a re m a in ta in e d w ith in th e o rg a n iz a tio n , h o w th e cu rr e n ts ta tu s is e st a b lis h e d ,a n d h o w th e re le va n t in fo rm at io n is ca s ca d e d to th e s ho p fl o or w it h in th e tw o -w e e k p e ri o d . T h e o rg a n iz a tio n sh a ll id e n tif y w ho is re s p o n si b le fo r p e rf o rm in g th e s e ta s ks . T h e h e a t tr e a te r s ha ll h a v e w rit te n p ro c e ss s p e ci fic at io n s fo r a ll a c tiv e pr o ce s se s a n d id e n ti fy a ll s te ps o f th e p ro c e ss in c lu d in g re le v a nt o p e ra ti n g p a ra m e te rs . E x a m p le s o f o p e ra tin g p a ra m e te rs in c lu d e p ro ce s s te m p e ra tu re s, c yc le ti m es , lo a d ra te s , at m o s ph e re o r g as flo w s e tti n g s, b e lt s p e e d s, q u e n ch a g ita ti on s p e ed s , e tc . S u ch p a ra m e te rs sh a ll n o t o nl y b e d e fi ne d , th e y s h a ll h a v e o p e ra ti n g to le ra n ce s a s d e fin e d b y th e o rg a n iz a ti o n in o rd e r to m a in ta in p ro c e ss co n tr o l. A ll a ct iv e p ro c e ss e s s h ou ld h av e a w ri tt en p ro c e ss s p e ci fic at io n . T h es e p ro ce s s s p ec ifi c at io n s m a y ta k e th e fo rm o f w o rk in s tr u c tio n s, jo b ca rd , c o m p u te r-b as e d re c ip e s , o r o th e r si m ila r d o cu m e n ts .

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A re a ll h e a t tr e a t re la te d a n d re fe re n ce d s p ec ifi ca ti o n s cu rr e n t an d a v ai la b le ? F o r E xa m p le : S A E ; A IA G ,A S T M , G e n e ra lM o to rs , F o rd , a n d D ai m le rC h ry s le r. Is th er e a w rit te n p ro c e ss sp e ci fic a tio n fo r a ll a c tiv e p ro ce s se s?

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T o d e m o ns tr a te e a ch p ro c es s is c a p a bl e o f yi e ld in g a c ce p ta b le p ro d u c t th e o rg a n iz a ti o n s h a ll p e rf o rm p ro d u ct c a pa b ili ty s tu d y fo r th e in it ia l va lid a ti on o f e a ch p ro c e ss , a fte r re lo c a tio n o f a ny p ro ce s s e q u ip m e n t, & af te r a m a jo r re b u ild o fa n y e q ui p m e n t. T h e o rg an iz a ti o n sh a ll d e fin e w h a t co n s tit u te s a m a jo r re b u ild .I n it ia l p ro d u ct c ap a b ili ty st u d ie s s ha ll b e c on d u c te d fo r a ll h e a t tr e a t p ro ce s se s p er fu rn a ce lin e d e fin e d in s co p e o f w o rk & in ac co rd an c e w ith c u st o m e r re q u ir e m en ts . A fu rn ac e lin e m a y in c lu d e a co m b in a ti o n of e q ui p m e n tt h a t is in te g ra te d in th e p e rf o rm a n c e of a h ea t tr e a tm e n t p ro ce s s, e .g ., h a rd e ni n g , q u e nc h in g , a n d te m p e ri n g . C a pa b ili ty s tu d y te ch n iq u e s sh a ll b e a p pr o p ria te fo r th e h e a tt re at p ro d u ct c h ar a ct e ri st ic s , e .g ., te n s ile st re n g th , ca s e d e p th , h a rd n e ss . A ny sp e c ifi c c u st o m e r re q u ir e m en ts sh a ll b e m et , in th e a b s en c e o f cu s to m e r re q u ir em e n ts , th e o rg a n iz a tio n s h al l e st a b lis h a c ce p ta b le ra n g e s fo r m ea s u re s o f ca p a b ili ty . A n a c tio n p la n s h a ll ex is t to a dd re ss th e st e p s to fo llo w e d in c a se c ap a b ili ty in di c es fa ll o u ts id e c u st o m e r re q u ir e m e n ts o r e st a b lis h ed ra n g e s . T h e a n al y si s o f p ro d u ct s a nd p ro c e ss e s o v er tim e ca n yi e ld v ita l in fo rm a ti o n fo r de fe c t pr e ve n tio n e ff o rt s. T he o rg a n iz a ti on s h al l ha v e a sy st e m to co lle c t, a na ly z e , an d re a c t to pr o d uc t o r p ro c es s d a ta o v e r tim e . M e th o d s o fa n a ly s is sh a ll in c lu d e o n g o in g tr e n d o r h is to ri ca ld a ta a n a ly si s o f si g n ifi ca n t p ro d u ct o r p ro ce s s p a ra m e te rs . T h e or g a ni z at io n sh a ll d e te rm in e w h ic h p a ra m et e rs to in c lu d e in s u ch a n a ly si s.

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H a s a va lid ca p a b ili ty st u d y b e e n p e rf o rm e d in iti a lly a n d a ft e r p ro c e ss e q ui p m e nt ha s b e en re lo ca te d , o r h a d a m a jo r re b ui ld ? D o e s th e h e a t tr e a te r c ol le c t a n d a n al yz e d a ta o v e r tim e , an d re a c t to th is d a ta ?

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M a n a g e m e n t s h al lr e vi e w th e fu rn a c e m o n it o ri ng s ys te m s a t in te rv a ls n o tt o e xc e e d 2 4 h o u rs . T h e h e a t tr e a t m o ni to ri n g s ys te m in cl u d e s b u t is n o t lim it e d to te m p e ra tu re st ri p c h ar ts , a tm o sp h e re s tr ip c h a rt s, c o m p ut e r da ta lo gs , fu rn a ce a n d o p e ra to r lo g s, e tc . T h e m a n a g e m e n t re v ie w s h al l in c lu d e e ff o rt s to d e te ct o u t-o f-co n tr o lc o n d iti o n s o r a la rm co n d iti o ns . T h e p ro c e ss o fr e vi e w in g th e fu rn a ce d a ta s h a ll b e d o c um e n te d a n d th is re q u ir e m e n t al so a p p lie s to c o m pu te ri z ed d a ta . T h e o rg a n iz a ti o n s h a ll co n d u ct in te rn a l a s se s sm e n ts o n a n an n u a l ba s is , a t a m in im u m , u s in g th e A IA G H T S A . T h e q u a lit y m a n a g e m e nt s ys te m s h a ll in c lu d e a d o c um e n te d p ro ce s s fo r re pr o ce s si n g th a t sh a ll in cl u d e a u th o ri za ti o n fr o m a d e si g n a te d in d iv id u a l. T h e re pr o ce s si n g p ro c e d u re sh a ll d e sc ri b e pr o d uc t c h a ra ct e ri s tic s fo r w h ic h re p ro c e ss in g is a llo w e d a s w e ll a s th os e ch a ra c te ris tic s fo r w hi c h re p ro ce ss in g is n o t p e rm is si b le . A n y re pr o ce s si n g a c tiv ity sh a ll re q u ir e a ne w p ro c e ss in g c on tr ol s he e t is s u ed b y q ua li fie d te c h ni ca l p e rs o n n e l de n o ti n g th e n e ce s sa ry h e a t tr e at m o d ifi ca ti o n s. R e co rd s s ha ll c le a rl y in d ic a te w h e n a n d ho w a n y m a te ri a lh a s b ee n re p ro ce ss e d . T h e Q u al it y M a n a ge r o r a d es ig n e e sh a ll a u th o ri ze th e re le as e o f re p ro c es se d p ro d u c t. T h e q u a lit y m a n a g e m e nt s ys te m s h a ll in c lu d e a p ro c e ss fo r d o cu m e n tin g , re vi e w in g, a n d a d d re s si n g c u st o m e r c o nc e rn s a nd a n y o th e r c o n ce rn s in te rn a l to th e o rg a n iz a tio n . A d is ci pl in e d p ro b le m -s o lv in g a pp ro ac h sh a ll b e u se d .

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Is m a n a g em e n t re v ie w in g th e h e a t tr e a t m o ni to ri n g s ys te m e v e ry 2 4 h o u rs ? A re in te rn a l a ss e ss m e n ts be in g co m p le te d o n an a n n u a l b a si s, a t a m in im u m , u si n g A IA G H T S A ? Is th e re a s ys te m in pl a ce to a u th o ri ze re p ro c e ss in g a n d is it d o c u m e n te d ? D o e s th e Q u a lit y D e p a rt m e n t re v ie w , a d d re ss , a nd d oc u m e nt c u st o m e r a n d in te rn a l co n ce rn s?

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T h e h e a t tr e a te r s ha ll d e fi n e a p ro c e ss fo r c o n tin u a li m p ro ve m e n t fo r e ac h h e a tt re a t pr o ce s s id e n tif ie d in th e s co p e o f th e H T S A . T h e p ro c e ss s h a ll b e d e s ig n e d to br in g a b o u tc o n tin u a l im p ro ve m e n t in q u a lit y a n d p ro d u ct iv it y. Id e n tif ie d a c tio n s s h a ll b e pr io ri tiz e d a n d s h a ll in c lu d e tim in g (e s ti m a te d co m p le ti o n d at e s ). T h e o rg a n iz a tio n s h a ll sh o w e vi d e n ce o f p ro g ra m e ffe c tiv e n e ss . T h e Q u al it y M a n a ge r is re sp o n si b le fo r au th o ri zi n g a n d d o cu m e n tin g a p p ro p ri at e p e rs o n n e lt o d is p o s iti o n q u a ra n ti n e m a te ri a l. T h er e sh a ll b e p ro ce d u re s or w o rk in st ru ct io ns a v a ila bl e to h ea t tr e a t p e rs o n ne l co v e ri ng th e h e a t tr e at in g p ro ce s s. T h e s e p ro c e d u re s o r w or k in st ru c tio n s sh a ll in c lu d e m e th o ds o f a d dr es s in g p o te n tia l e m e rg en c ie s (s uc h a s p o w e r fa ilu re ), e q u ip m e n t st a rt -u p , eq u ip m en t s h ut -d o w n, p ro du c t s e g re g a tio n (S e e 2. 8 ) pr o d uc t in s p e ct io n, a n d g e n e ra l o pe ra ti n g p ro ce d u re s . T h e se p ro c e du re s o r w or k in st ru c tio n s sh a ll b e a cc e s si b le to s ho p fl o o r p e rs on n e l. T h e o rg a n iz a ti o n s h a ll p ro vi d e e m p lo ye e tr a in in g fo r a ll h e a t tr e a ti ng o p e ra ti o ns . A ll em p lo ye e s, in cl u di n g b a ck u p a n d te m p or a ry em p lo ye e s, s h al l b e tr a in ed . D o c u m e n te d e vi d e n ce sh a ll b e m a in ta in e d s h o w in g th e e m pl o ye e s tr a in e d a n d th e e ff e ct iv e n e s s o f th e tr a in in g. M a n a g e m en t s h al l d e fi ne th e q u a lif ic a tio n re q u ir e m e n ts fo r e a ch fu n ct io n , a nd o n g o in g o r fo llo w -u p tr ai n in g s h al l a ls o b e a d dr e ss e d.

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Is th e re a co n ti n u al im p ro v e m en t p la n a p p lic a bl e to e ac h p ro ce s s d e fi ne d in th e sc o p e o f th e a ss e ss m en t? D e s th e Q u a lit y M a n a g e r o r d e si g ne e a u th o ri ze th e d is po s iti o n o fm a te ri a lf ro m q ua ra nt in e st a tu s? Is th e re p ro c e d ur e s o r w o rk in st ru c tio n s av a ila b le to th e he a t tr e a t p e rs on n e l th a t d ef in e th e h e a t tr e a tin g p ro c e ss ? Is m a n a g e m e nt p ro v id in g e m pl o y ee tr a in in g fo r h e a t tr e a tin g ?

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T h e o rg a n iz a ti o n s h a ll m ai n ta in a re s p o ns ib ili ty m a tr ix id e n tif yi n g a ll ke y m a n a g e m e nt a n d s u p er vi so ry fu n ct io n s a n d th e q u a lif ie d p e rs o n n el w h o m a y p e rf o rm s u ch fu n ct io n s. It sh a ll id en ti fy b o th p ri m ar y a n d se c o nd a ry (b a c ku p ) p e rs o n n el fo r th e ke y fu n ct io n s (a s d e fi n e d b y th e o rg an iz a ti o n) . T hi s m a tr ix s h a ll b e re a di ly a v ai la b le to m a n a g e m e n t a t a ll tim e s . T h e o rg a n iz a ti o n s h a ll h av e a d oc u m e n te d p re v e n tiv e m a in te na n c e pr o g ra m fo r ke y pr o ce s s e q u ip m e n t (a s id e n tif ie d by th e o rg a ni z at io n ). T h e p ro g ra m s h al l b e a c lo s e d-lo o p p ro c es s th a t tr a c ks m a in te n a n ce e ff o rt s fr o m re q u e st to co m p le ti o n to a s se s sm e n t of e ff e c tiv en e s s. E q u ip m e n to p e ra to rs s h a ll h av e th e o p p o rt u n it y to re p o rt p ro b le m s , a nd p ro b le m s s ha ll a ls o b e h a n dl e d in a cl o se d -l o o p m a n n e r. C o m p a n y d a ta , e .g ., d o w n ti m e , q u a lit y re je ct s , fir st -ti m e -t h ro u g h ca p a b ili ty , re cu rr in g m a in te n a n ce w o rk o rd e rs , a nd o p e ra to r-re p o rt e d p ro b le m s ,s h a ll b e u se d to im p ro v e th e p re ve n tiv e m ai n te n an c e p ro g ra m . F ur n ac e s a n d g e n e ra to rs s h a ll b e s ch e d u le d fo r b u rn -o ut a t fr e q u e n ci e s d e te rm in e d b y th e o rg a n iz a ti o n (s e e S ec ti on 1 o f th e P ro c e ss T a bl e s) . M a in te n a n ce d a ta sh a ll b e co lle c te d an d a n a ly ze d a s p ar t of a p re d ic ti ve m a in te n a n ce p ro g ra m . T h e h e a t tr e a te r s ha ll d e v e lo p a n d m a in ta in a c ri tic al s p ar e pa rt s lis ta n d s h al le n s u re th e a v a ila bi lit y of s u ch p a rt s to m in im iz e p ro d u ct io n d is ru p ti o n s.

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Is th e re a re s p o n si b ili ty m at ri x to e n su re th a t a ll ke y m a n a g e m e n t a n d su p e rv is o ry fu n ct io n s a re p e rf o rm e d b y q u a lif ie d p e rs o n n el ? Is th e re a p re ve n ti ve m ai n te n a nc e p ro g ra m ? Is m a in te n a n ce d a ta b ei n g u til iz e d to fo rm a p re d ic ti ve m a in te na n c e pr o gr a m ? H a s th e H e a t T re a te r d e ve lo p e d a cr iti ca l sp a re p a rt lis ta n d a re th e p a rt s a v a ila bl e to m in im iz e p ro d u ct io n di sr u p tio n s?

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It is c ri tic a l th a ta ll c u st o m e r re q u ir e m e n ts a n d lo t id e n tif ic a tio n b e a d e qu a te ly tr a n s fe rr e d to in te rn a l h e a t tr e a t d o cu m e n ts . T h e fa ci lit y s h a ll e ns u re th a t th e d a ta en te re d in th e re c e iv in g s ys te m m a tc h th e in fo rm a tio n o n th e c u st o m e r's sh ip p in g d o cu m e n ts . D o c u m e n te d p ro c es se s a n d e v id e n c e o f c o m pl ia n c e sh a ll e xi st , e .g ., sh o p tr a v el e rs , w o rk o rd e rs , e tc . S o m e tim e s th e m a te ri a l re c ei ve d d o e s n o t p re c is el y co rr es p o n d to c u st o m e r s hi p p in g d o c um e n ts .T h e fa c ili ty sh a ll h a ve a d e ta ile d p ro c e ss in p la c e to re so lv e re c e iv in g d is c re p a n ci e s. T h e re qu ir e m e n ts s ta te d a b o ve a ls o a p p ly to c a p tiv e h e a t tr e a t d e p a rt m e nt s . T h is p ro c es s re fe rs to re c e iv in g a n d sh ip p in g th e p a rt s in a n d o u t o f th e h e a t tr e a t d e p ar tm e nt . P ro c e du re s fo r p a rt a n d co n ta in e r id e n tif ic a ti o n h e lp to a v oi d in c o rr e c t p ro ce s si n g or m ix in g o f lo ts . A p p ro p ri a te lo ca ti o n an d s ta g in g w ith in th e fa ci lit y a ls o h e lp to e n su re th a t o rd e rs a re n o t sh ip p e d u n ti la ll re q u ir e d o pe ra ti o n s a re p e rf o rm ed . C u s to m e r pr o d uc t sh a ll b e cl e a rl y id en ti fie d a n d s ta g ed th ro u g h o u t th e h e a t tr e a t p ro ce s s. N o n -h e a t tr e a te d , in -p ro c e ss , a n d fi n is h e d p ro d uc t sh a ll b e p ro p e rl y s e g re g a te d a n d id e n ti fie d . A ll m a te ri a l s h a ll b e s ta g ed in a de d ic a te d a n d c le a rl y d ef in e d a re a . O u t-g o in g lo t( s) s h a ll b e tr a ce a b le to th e in c o m in g lo t( s ). T h e d is c ip lin e o f p re ci s el y id e n tif y in g lo ts an d lin k in g a ll p e rt in en t in fo rm a tio n to th e m e n h a nc e s th e a b ili ty to do ro ot c a u se a n a ly si s a n d co n ti n ua l im p ro ve m e n t.

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D o e s th e fa c ili ty e ns u re th a t th e d a ta e nt e re d in th e re ce iv in g s ys te m m a tc h es th e in fo rm a tio n o n th e cu st om e r' s s h ip p in g d o c u m e n ts ? Is p ro d u c t cl e a rly id e n ti fie d a nd s ta ge d th ro u g h o u t th e he a t tr e a t p ro c e ss ? Is lo t tr a c e a bi lit y an d in te g ri ty m a in ta in ed th ro u g h o u t a ll p ro ce s se s?

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T h e c o n tr o lo f s us p e ct o r n o n -c o n fo rm in g p ro d u ct is n e c es s ar y to p re v en t in a dv e rt e n t sh ip m e n t o r c o n ta m in a tio n o f ot h e r lo ts . P ro c e du re s s ha ll b e a d e q u a te to p re v e n t m o v e m e n t o f n o n -c o n fo rm in g p ro d u c t in to th e pr o d uc tio n s ys te m . P ro c ed u re s s h a ll e xi st a d d re ss in g p ro p e r d is p o si ti o n, p ro d u c t id e n tif ic a tio n , a n d tr a ck in g o f m a te ria l flo w in an d o u t o f th e h o ld a re a .A n o n -c o nf o rm in g h ol d a re a s h a ll b e c le a rl y de s ig n a te d to m a in ta in se g re g a ti o n o f s uc h m a te ri a l. H e a t-tr e at in g fu rn a ce s an d o th e r p ro c e ss in g e q u ip m e n t co n ta in a re as th a t ha v e a ri s k o f tr a pp in g o r h ol d in g p a rt s . S u c h tr a p p in g o f p ar ts c a n le a d to d a m a g e , im p ro p e rl y p ro c e ss e d pa rt s o r lo t m ix in g /c o n ta m in a ti o n. A sy st e m s ha ll e x is t to id e n tif y tr a p p o in ts in th e e n tir e h ea t tr e a t p ro c e ss to re d u c e ri s k o f m ix e d p ar ts (i n a p p ro p ri a te , n o n -h e a t tr e a te d , or im p ro p e ry h e at tr e at e d p a rt s ). T h e h e a t tr e a te r s ha ll h a v e do c u m en te d p ro c ed u re s to id e n tif y a n d m o n ito r tr a p p o in ts fo r e a ch p ro c e ss /e q ui p m e nt . M o n ito ri n g o f p o te n ti a lt ra p p o in ts sh a ll o c cu r fo r e v e ry pa rt c h a n g e ov e r. C o n ta in e rs h a n d lin g c u st o m e r p ro d u c t sh a ll b e fr e e o f in ap p ro p ri a te m a te ri a l. A ft e r e m p ty in g a nd b e fo re re -u si ng c o n ta in e rs ,c o n ta in e rs sh a ll b e in sp e c te d to e n su re th a t a ll p a rt s a n d in ap p ro p ri a te m a te ri a lh a ve b e e n re m o ve d . T h e so u rc e o f in a p pr o pr ia te m a te ri al sh a ll b e id en ti fie d a n d a d d re s se d . T h is is to e n su re th a t n o n o n co n fo rm in g he a t tr e a te d p a rt s o r in a p p ro p ri a te m a te ri a lc o nt a m in at e th e fin is h e d lo t.

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A re p ro c ed u re s a d e qu a te to pr e ve n t m o ve m e n t of n o n -c on fo rm in g p ro d uc t in to th e p ro d u c tio n sy st e m ? Is th e re a s ys te m to id e n ti fy tr a p p oi n ts in th e e n ti re h ea t tr e at p ro c e ss to re d u ce ri sk o f m ix e d p a rt s (i n a p pr o p ria te , n on -h ea d tr ea te d , o r im p ro p e rl y h e a t tr e a te d pa rt s) ? A re co n ta in e rs fr e e o f in a p p ro p ri a te m a te ri a l?

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F u rn a ce lo a d in g p a ra m e te rs sh a ll b e sp e c ifi e d, d o c um e n te d , a n d c o n tr o lle d .E x a m p le s in cl u d e fe e d ra te , b e lt s pe e d , n u m b er o f pa rt s p e r fi xt u re , a n d lo a d w e ig h t. R e fe r to P ro ce s s T ab le s, S e ct io n 3 .0 , fo r fr e q u e n cy o fc h e ck s. U n p la nn e d o r e m e rg e n cy d o w n tim e g re a tly ra is e s th e ri sk o f im p ro p e r p ro c e ss in g . O p e ra to rs sh a ll b e tr ai n e d in m a te ri al h a n dl in g , c o nt ai n m e nt a c tio n , a n d p ro d u ct s e g re g at io n in th e e ve n t o f a n e q u ip m e n t e m e rg e n cy in cl u d in g p o w e r fa ilu re . T ra in in g s h a ll b e do c u m en te d . W o rk in st ru c tio n s s p e ci fic al ly a d d re ss in g p o te n tia l ty p e s o f e q u ip m e n t e m e rg e n ci e s a n d fa ilu re s s h al lb e a c ce s si bl e to a n d u n d e rs to od b y e qu ip m en t o p e ra to rs . T h e se in st ru c tio n s sh a ll a d dr e ss c o n ta in m e nt a c tio n s re la te d to al l el e m e n ts o f th e h e a t-tr ea ti n g pr o ce s s, e .g ., lo a d in g , a u st e n ti zi ng , q u e n ch in g ,t e m p e ri n g . H a n d lin g , st o ra g e , a n d p ac ka g in g sh a ll b e a d e q u a te to p re s e rv e p ro d u c t q u al ity . T h e h e a t tr e at e r’ s fu rn ac e lo a d in g s ys te m , in -p ro c e ss h a n d lin g a nd s h ip p in g p ro c e ss sh a ll b e a ss e ss e s fo r ri s k o f p a rt d a m a ge o r o th e r q u a lit y co n ce rn s . S o m e eq u ip m e n t in cl u de s co n v ey o rs a nd o th e r m o vi n g co m p o n e nt s th a tm a y n ot b e a b le to h a n d le a ll p a rt c o n fig u ra ti on s . O th e r p ra c tic e s s u ch a s s ta ck in g o f o ve rl o a d ed c o n ta in e rs c a n a ls o in cr ea s e th e ri s k o f p a rt d a m a ge .

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Is fu rn ac e lo a d in g s p ec ifi e d d o c u m e n te d a n d c o n tr o lle d ? A re o pe ra to rs tr ai n e d in m at e ri a l h an d lin g , co n ta in m e n t a ct io n a n d p ro d u ct s e g re g a tio n in th e e ve n t o f a n e q ui p m e nt e m e rg e n c y in c lu d in g p o w e r fa ilu re ? Is th e h a n d lin g , st o ra g e a n d p a ck a g in g a d e qu a te to p re s e rv e p ro d u c tq u a lit y

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References

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