Special Process: Plating System Asse

Version 1

Special Process: Plating System Assessment

Facmty Name: DeKalb Metal Finishing

Address: 625 West 15th Street / PO Box 70 Auburn. IN 46706
Phone Number: 260-92S-1820 Typets) o'f Plat ng Processing at this Facility’:
Fax Number: 260-925-5258 Process Table A
Zinc
Number of Plating Employees at this Facility: 31 Zinc Alloy Plating
Captive Plater fY/N): NO Process Table B
commercial Plater //N): Yes Surface Conditioning of
Metals for Decorative Plating

Date of Assessment: 1-Jan-2010 Process Yabfe C

Surface Conditioning of ABS
& PCABS Plastics for
Decorative Plating
Date of Prev ous Assessment: 1-Jan-2009 Process Table D
Decorative Plating
Process Table E
Mechanical Plañng
Process Table F
Equ pment
Process Equipment
Current Quality Cezfificat\on{s): ISO/TS 16949:2002

Date of Re-assessment tel necessary'):

Personnel Contacted:
Title: Phone• Email;
Dave I•4ouser Plant Manager 260-925-1820 M.16
Paul Fry Lab Manager 260-925-1820 M.15
Matt Moms Ouality/Systems Manager 260-925-1820 Ext.J4

Audftozs/Assessors:
Name: Company: Phone:
Matt Moms DeKalb Metal Finishing 260-925-1820 M.14

Number of "Not Satiatactory" Findings:

Number of "Fall" Findings n the Job Aud Us):

 CQI-11
Special Process: Plating System Assessment
Version 1 Issued 0/07

Assessment

g Processing at this Facility’:

Yes
Yes

No

NO

No

No

Yes
Yes

Email;
dhouser@[Link]
pfry@deka![Link]
mmoms@[Link]

Email:
mmoms@[Link]
 Special Process: Plating Process Assessment (General Facility Overview

Oueetlon Requirements and Guldance

Number
Section 1 - Management Re
To ensure readlly 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
Is there a dedicated and organiza8on chart. A job description shall
1.1 qualified plating person exist identifying the qualifications for the
on- slte? position Including chemlcal and plating
knowledge. The qualifications shall Include a
minimum of 5 yearn experlence In plaling
and surface finlshlng or a combination of
formal chemlstry/chemlcal engineering
education and plating experlence totaling a
The organization shall incorporate a
documented advance quality plannlng
procedure. A feasIbi|ity study shall be
performed and internally approved for each
Does the plater perform part. Similar pans can be grouped jnto part
1.2 advanced quality famlllea for thls effort as defined by the
planning? organlzatfon. After the part approval process is
approved by the customer, no process changes
are allowed unleGs approved by the customer.
The plater shall contact the customer when
clarification of process changes Is required. Thl9
Clerification of process changes shall be
 COl-4 4
Special Process: Pfatinp 4ystem Assessment
g Process Assessment (General Facility Overview)

Objective Evldanee N/A Satisfactory Not Satisfactory Needs Immediate

Actlon

sponsibility and Quality Plannin j

DeKalb Metal FInIsh1ng's Lab Manager has

more than 20 yearn of experience in the
platlng/surface fIn!sh1ng industry'.
The Job Description for the position of Lab
Manager reflects tile requirement.

DeKalb Metal Flnlshlng uses the AIAG

manual as a reference for conducting
APQP's. In addition, we ufillze
Procedure 37 to furlher define our APQP
poli¢y. Feaslb!lity studles are done for
each part and are malntalned both In
hard ¢opy and electronic format.
 Special Process: Plating Process Assessment (General Facility Overview

Question QuB8{lOn Requirements end Guidance

The organizatlon shall Incorporate the use of a

documented Failure Mode and Effects Analysls
(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 or tfiey may be process-specific and
written for each process. In any caee, they
shall address all proseas steps from part
Are plater FMEA's up to date receipt to part shlpment and 8II key plating
1.3 and reflecting current process parameters as defined by the
processing2 organlzacon. A cross-functional team shall be
used In the development of the FMEA. All
characteristics, as defined by the organization
and lte customer, shall be Idenflfied, defined,
and addressed In the FMEA.

The organlzation shall ino0rporate the use of

a documented Control Plan procedure and
ensure the Control Plans are updated to reflect
current controls. The Control Plans shall be
wrltten for each part or part famlly or they may
be proceae-specific and written for each
process. In any ase, they shall address all
process steps from part receipt to part
Are finish process control shlpment and Identify all equipment ueed and
plana up to date and all key plating process parameters as defined by
1.4
reflecting current the organjzatlon. A cross-functional team,
processing’/ including a productlon operator, shall be used in
the development of Control Plans, whlch shall
be conslstent with all assoclated documentation
such as work instructions, shop traveler, and
FMEAS. All speclal characterlstlcs, as defined by
the organization and its customers, shall be
identified, defined, and addressed In the Control
Plans. Sample sizes and Frequencles for
evaluation of process and product
Characteris8cs shall also be addressed
 CQI-11
Special Process: Plating System Assessment
Version 1 issue0 8/07

g Process Assessment (General Facility Overview)

Objectlye Evidence NeedeA

Immediate

De aI6 Metal Ffnlshlng vses ffie AIAG manual as a

reference for conducting FMEA's. In eddlyon, we
utilize Procedure 3T to further deflne our FMEA
policy. FMEAs are process dñven and have been
created for each process line (I.e. line 1, IIne 2,
elc.).

DeKalb Melee Finishing uses lhe AIAG menuel

as a reference for conductlng Control Plans.
In addltlon, we utilize Procedure 35, to
further define our Control Plan policy .
Control Plans ere elected electronlcally ana
are directly llnked la our jab controls In order
Io ensure thet chenges la the contra] plan are
ImmedietTy communicated to all affected
 Special Process: Plating Process Assessment (General Facility Ove

Oueetlon Requlrements and Guldanee

To ensure all customer requlrements are both

undemtood and satisfied, the organization
shall have all related platlng and customer
referenced standards and specifications
available for use and a method to ensura that
they are current. Such standards and
speeificatlons include, but are not limiled to,
those relevant documents published by SAE,
AiAG, ASTM, General Motom. Ford, and
Are all plating related and DalmlerChrysler. The
referenced ape¢)flcationa oreanization *hall have a proseas to endure the
current and avallable? For timely revlew, distribution, and implementatlon
1.5 example: SAE, AUG, of all customer and industry engineering
ASTM, General Motors, standards and specifications and changes
Ford, and baaed on customer- required achedule. Thls
DaimlerChrysler. process shall be executed as soon as posslble
and ahall not exœed two weeks. The
organlzation shall document thls proœss of
revlew and Implementation, and lt shall address
how customer and industry documenb ere
obtained, how they are maintalned withln the
organ)zatIon, how the current statue la
establlshed, and how the relevant infomatlon is
cascaded to the shop floor wtthln the two-week
period. The organization shall identify who ls
fesponglble for perfomlng thèse te*ks.
 CQI-11
Special Process: Plating System Assessment
Version 1 lssuad 8/07

rocess Assessment (General Facility Overview)

Objective Evîdence N/A

Satlefactor Not N•••
e lmmedlate
y Satlyfactory Action

», une d Mm» s are senf to us by our cualomers.

y

AdditJ»naIly, we subscrlbe to a
service that notGes us when
speclflcaflons are updaled. A)T
dooJments are controlled
electronÏcally In our document
managemenl ""”a’"-
 Special Process: Plating Process Assessment (General Facility Over

Ctueetlo Requlraments and Guldance

n
Number
The plater shall have written process
apecificatione for all active promesses and
identify all steps of the process including
relevant operating parameter8. Exemples of
operatlng parametem lnclude prooese
temperatures, cycle times, load rates, rectifier
Il there a writtan process gettings, etc. Such parametem shall not only be
1.6 speclflcation for all active deflned, they shall have operating tolerancee aa
processes? defined by the organlzation in order to malntain
process control. AII actlve prooesaes ehould
have a written process specification. Thèse
proœss apecigcadons may take the form of
work lnstructfona, job card, œmputer-based
recipes, or other s1miIar documents.

To demonstrate each process Is capable of

yielding acceptable product the organization
shall perfom product capability studies for
the lnI8aI validation of eaeh process, afrer
refocatiofl of and proies equipment, and afler a
major rebuild of any equipment. The
organization shall define what constitutes a
major rebuild. Initial product capablI!ty
studies shall be oonducted for all plating
proceetes per lina as defined In scope of work
Has a va1Id product and in accordance wlth customer requlremente.
capabllily study been Capabllliy study technlquas shall be appropriate
1.7 for the pla8ng product characteñsflcs, e.g. plate
performed InTtlally and
thlckness. corroslon resistance. etc.. Any
after process cfiange2
speUfi¢ customer requlrements ghalI be met. In
the absence of customer requirements, The
organization shall establish acceptable ranges
for measures of capability. An acgon plan afraid
exist to address the steps to be followed in case
capablllty’ Indices fall outslde customer
requirements or establlshed ranges.
 CQI-J1
Special Process: Pïaffng Systerri Assessment
Version 1 issued &07

Process Assessment (General Facility Overview)

Objective Ev}dence Neede Immedlate

Job Selup InslMctlons ere In place for each

recommended cycle times, recommended
recUler settings, pleces per rack, racks per
frame, required engineering apeclficaGon,
color, thlclwess requirements, racking
requlremenfs, packaging requlremenls, and
olher special requTremenle, as defined by
X

Product capability studies ere perfumed

annually by telling perts and panels against
tha most stringent speclficatlons we are
requlred to meet. Tested cheractor¡stlcs
Include corrosion ieslslence and casting
thlckness. Mere applicable, edheslon, nickel
œntent and olher cuslomer specffled
AddTtlonally. cepeblllty Studies are parfomed
after a major rebulld of lhe llne (repÏaclng the
head).
 Special Process: Plating Process Assessment (General Facility Overview

Question Requirements and Guidance

Does the plater collect The analysis of products and processes over
and analyze data over time can yield vital infomation for defect
time, and react to this prevention efforts. The organlzation shall have
data? a system to collect. analyze, and react to
product or process data over time. Methods of
1.8 anaiysis shall Include ongolng trend or hlgtorlcal
data analysis of special product or
@@ qa/ame!ers The @ggqj §@ $|jgjj
detemlne which parameters to include in such

Does management revlew Management shall review the oven monltoring

and verlfy bake oven logs systems/logs at intervals not to exceed 24 hours
for parts requiring hydrogen or prlor to parts belng released for shipment.
1.9 embrittlement relief every The plater shall have reaction plans for non-
24 houm? conformances to process requlrements. Thls Is
to oontaln, et minimum, requirements for
quarantlning materlal and notifying customer.
1.10 Are internal assessments The organlzation shall conduct Internal
being completed on an assessments on an annual bask, at a mlnlmum,
annual basls, at a mlnlmum, using the AIAG PSI. Concerns shall be
addressed In a tlmely
 CQI-J1
Special Process• Plating System Assessment
Version 1 Issued 8/07

g Process Assessment (General Facility Overview)

Obtectlve Evldence N/A satisfactory Not Satlcfactory

D»x»lb M» »I Flnlsnlng uses and electronic

system for gathering, storing, and
analyzing most typea of dala. Th1s data Is
analyzed on
•• ••g•!•g b8g|g to fflake decl9lon on lab,
produWon 8nd qua)lty managemgnl.
 Special Process: Plating Process Assessment (General Facility Ove

Qu8BtlOA Question Requirements and Guidance

NuTflb6F

Tne quality management syatem shall

Include a documented process for
reprocesslng that shall Include authorizaflon
from a designated lndlvidual. Tfie
reprocessing procedure shall describe
product characteristics for whlch
reprocessing Is allowed as well as those
Is Ihere a system In place characteristics for whlch reprocesslng is not
1.1 1 to authorize reprocessing pemlssible. All reprocessing activity shall
and is it documented? require a new processing control sheet
issued by qualified technical pemonnel
denoting the neoessary plating modifications.
Records shall deady indicate when and how
any matei1al has been reprocessed. The
Quallty Manager or a designer shall authorlze
the release of reprocessed product.
Does the Quality The quality management system ahall Include a
Department review, process for documenflng, revlewing, and
address, and document addressing customer concerns and any other
1.12 concerns internal to the organizatlon. A
customer and Internal
concerned disclpllned problem-solving approach shall be
used.
Is there a continual The plater shall define a process for
Improvement plan conflnual improvement for each plating
applicable to each process ldenflfled In the scope of the PSA.
process defineo In the The prooess shall be deslgned to br!ng about
gcope of the continual improvement in quality and
assessment? productivity. Identified actlons shall be
pdoñtlzed and shall include tlmlng
(estimated completion dates).
The organization shall show evidence of
Does the Quality Manager or The Quality Manager or designee ie
designee authorize the
program effectiveness.
responslble for authorizing and documenting
1.14 disposition of mateñal from appropriate personnel to disposition
quarantine status?' quaranflne materlal.
 CQI-11
Special Process: Pfatfng System Assessment
Version 1 Valued 8/07

rocess Assessment (General Facility Overview)

Objective Evidence N/A

Satlcfactory Not Satlafactory Needs Immediate
Aetlon

DeKaTb Metel Finishing utilizes Procedure 40 la

menege the reprocessing. Referenced documents
Include Procedure 29 and Job Setup Instructions. X
Dpcumentallpn )s managea and stored
electronically.

DeKelb Metal Flnlshlng ullilzea and

electronic system for recording end menag|
fig customer complalnls, Inlemal rejects, and
external X

DeKalb Metal Fjn]sh}ng has a lhree ller (Red,

Yellow, Green) process management system
for conl oII!ng tha plating process end
meaeurlng process lmprovement. Tfl)s
systems Is monllored as part of management
revlew for effectlvefiess veilflcaflon.
 Special Process: Plating Process Assessment (General Facility Overvie

Ouestlon Requirements and Gulfiance

There shall be procedures and work instructlons

available to plating personnel covering the
plating process. These procedures or work
instructions shall include methods of addresslng
Are there procedures or
potential emergencies (such as power failure),
work Instructions available
equipment start-up, equipment shut-down,
1.15 to plating personnel that product segregation (See 2.8), product Inspectlon,
define the playing and general operating procedures. These
process? procedures or work instructions shall be
accessible to shop floor personnel.

The organization shall provide employee tralnlng

for all plating operations. All employees,
includlng backup and temporary employees,
shall be trained. Documented evidence ahall be
mainalned showing the employees tralned and
Is management providing the evidence shall include an assessment of
1.16
employee tralnlng for platlng? the effectiveness of the tralnlng. Management
shall define the qualification requirements for
each functlon, and ongolng or follow up tra!ning
shall also be addressed.

Is there a responsibllify The organlzaflon shall maintain a

matrix to ensure that all responslbllity matrix
key management and identifying all key management and
1.17 supervisory functions are supervisory funcgons and the qualified
performed by qualified personnel who may perfom auch functions.
personnel?
It shall Identify both prlmary and
seoondary (backup) personnel for the key
 CQI-11
Speria/ Process: Pfaifing Sysfiem Asserrment
VarsJori Issued B07

Process Assessment (General Facility Overview)

Objective Evidence M/A Satlefactoy Not Satlefectozy Needs Immediate

Action

Procedures, work instrucflons and olher

personnel through our eledronlc Document
Management software. Specific documents
include Procedure 08 (Contingency Plans).
Procedure 19 (Inspecgon and Testing), DUMI112
(Plant Sla tup/Shutdown), DMFWI071 (Llne 1
Stadup), DMFWI072 (Llne 1 Shutdown),
DMFWI073 (Une 2 Slertup), DMFWI074 (Line 2
Shutdown), DMFWI075 (Line 3 Stanup), DMMI076
(Llne 3 Sliuldoym), DMFWI07T (Line 4 Slertup),
DMFWI078 (Line 4 Shutdown)

DeKalb Metal Finishing educefes employees on

plating operatlone utilizing Program 1ooo and
Program 2000. Documented evldence Is
maInle]ned electronically In lour training software.

DeKalb Metal Finishing utilizes a

Reaponslblllfy Metrjx (DMF301) to enMre
that e1l key management and supery4aory
functions ere perfumed by qualNed
 Special Process: Plating Process Assessment (General Facility Over

oueetlon Requirements and Guidance

Number
The organization shall have a documented
preventive melntenance program for key
process equipment (as identified by the
organlzatlon). The program shall be a cloged-
loop pro¢ees that tracks maintenanoe efforts
from request to oompletlon to assessment of
effectiveness. Equipment operator shall have
the opportunlty to report problems, and
Is there a preventive problems shall also be handled In a posed-loop
malntenance program? Is manner. Company data, e.g., downtime, qualify
1.18 malntenance data being rejects, first time-through capability, reaun1ng
utilized to fom a predictive malntenance work orders, and operalor-reported
maintenance program? problems, shall be used to improve the
preventive maintenance program.
Malntenance data shall be collected and
analyzed as part of a predlcgve maintenance
program.

Has !he plater developed Ihe plafer shall develop and maintain a critical
a crIfla1 spare part list Mpa
1.16 parts IIst and shall ensure the availability of
and are the parts
available to minimize such re
productlon dlsrup8ons7 parta to minimize production dlsruptlons.
 CQI-11
Special Process: Pfatinp System Assessment
Process Assessment (General Facility Overview)

Objective Evidence
N/A Satlefactoz Not SatJefActory NeedeggIm|
y mediate

DeKalb Melal Flnlshlng ullllzes e spreedsheet

besed me]ntenance log to manage Ifs prevenllve /
predlctlve maintenance program (DMF261).

ne ci1tlcal spere pens IIsI Ie Included lhls In

the maintenance log (DMF261).
 AWotlYe Industry Achoo G roup

Special Process: Plating Process Assessment (General Facility Overvie

0ueetIon Requlremente and Guidance

Number

Section 2 - Floor and Ma

Does the facility ensure that Documented processes and evidence of
the data entered In the compllance shall exlat, e.g., shop travelers, work
2.1 receiving system matches the ordem, etc. The facility shall have a detailed
information on the customer's process In place to resolve receiving
shipping documented discrepancies.
Is product clearly identified Procedures for part and contalner identification
and staged throughout the help to avold incorrect processing or mixing of lots.
plating proceed? Appropriate location and staging within the
facility also help to ansure that ordera are not
afifpped unfil all requlred operations are
2.2 performed. Customer product shall be cleañy
Identified and staged 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 c!eañy defined area.
Is lot traceability and integrity Out-going lot(s) shall be traceable to the
malntalned throughout all incoming iot(s). The dlsclpline of precisely
2.3 processes? ldentify!ng late and llnklng all pertinent
Information to them enhanced the ability to do
root cause analysts and continual improvement.
Are procedures adequate to The control of suspect or non-confoming product
prevent movement of non- is necessary to prevent inadvertent shipment or
confomlng product inla the contamInat)on of other Iota. Prooedures sfiaTl
production systemI be adequate to prevent movement of non-
conforming product Into the produ¢tlon system.
2.4 Procedures shall exist addressing proper
disposition, product IdentI#catIon and tracking
of material how In and out of hold area. Non-
confoming hold area shal) be cleañy
deslgnated to malntaln segregation of such
material.
Ie there a system to Identify The plater ehall have documented
trap points in the entire procedures to Identlfy and monitor trap
2.5 plating process to reduce points for each process/equipment. Monitoring
risk of mixed parts of potential trep points shall occur for every
(Inappropriate, unfinished, part changeover.
or Improperly plated parts)?
 CQI-11
Special Process: Plating System Assessment
Version 1 Issued 8/07

Process Assessment (General Facility Overview)

Objective Evidence N/A Satisfactory Not Satlefaetory Needs Immedlate

Actlon

terial Handling Responsibility

oeKalb Metal Finishings recelving
document (DMF135 and DMF250) are
checked against customer Incoming
paperwork.

customer product Is typially Identlfied by

the customer on the packaging.
Additionally, DeXalb Metal Finishing labels
the product during the receiving process.
Once the plating prooess is completed,
plated parts are moved to the warehouse
where they are placed wlth "finished goods".

DeKalb Metal Finishing utilizes DMF135,

DMF250 and Trace Tags to maintaln lot
Integrin throughout all processes.

DeKalb Metal Finishing utilizes Procedure

29 to manage the Integrity of the non-
conforming / hold area to unsure
segregation of such materlal.

DeKalb Metal Fln]shlng has Identified trap

points and posted lhese findings on slgnage
healed lhroughouf the plant.
 COI-11
Special Process: 'Iating Sysfiem drresrmenf
A soIIve InddActon Group

Special Process: Plating Process Assessment (General Facility Overview)

Queatlon Ouestlon Requlramente and Guldence

Number

Containers handllng customer product shall be

free of inappropriate material. After emptying
and before re-ualng contalners. containers ahall
Are contalners free of be inspected to ensure that all parts and
inappropriate materials Inappropriate materlal have been removed.
The source of inappropriate material ahail be
identified and addressed. This 1s to ensure that
no nonconforming plating parB or
inappropriate materlal oontaminate the finlshed
2.7 Is part loading specified, Loading parameters shall be specified,
documented and documented and controlled. Examples
controlled7 Include parts per rack and load alze.
Are operator trained in Unplanned or emergency downtime greatly
material handling, ralaes the rlsk of improper processing.
containment action and Operators shall be trained in material
product segregation In the handling, oontalnment acgon, and product
event of an equipment
segregation in the event of an equlpment
emergency Includlng power
fallura? emergency lncludlng power failure. Tra1nIng
shall be documented. Work instructions
specifically addressing potentlal types of
equipment emergen¢lea and failures shall be
accessible to and understood by equlpment
operator. These instruJons shall address
containment/reaction plans related to all
elements of the proceaa. Evidence shall exlst
Is the handling, storage and the plater's loading/unloadlng systems, In
2.8 packeglng adequate to process handling and shlpping process shall be
preserve product quallty7 asaeseed for risk of part damage or other
quality concerns.
Are plant clean!!nese, Plant cleanllness, houaekeeplng, envlronmental,
househeeplng and and working oonditions shall be condudve to
environmental and controlling and Improving quality. The plater
working condit|pfjG should evaluate such oondiflons and their effect
2.10 on quality. A houseI‹eepIng policy shall be
conducive to conco and
improved quality? Clearly defined and executed. The facility shall
be reviewed for the following itams: loose parts
on floor; splllaga around tanks; overall plant
lighting; fumes etc.
 COI-11
Special Process: 'Iating Sysfiem drresrmenf

g Process Assessment (General Facility Overview)

Objective Evidence N/A SatTafactory Not Satlafactory Nee4s fmmedfate

Actlon
oeKalb Metal FIn1sh1ng uses customer
supplied containers.

DeKalb Metal Finishing utilizeg Job

Setup Instructions (DMF147) to speclfy
loading parameters. These documents
are controlled electronially.

DeKalb Metal Flnlsng trains operators on

material handling, containment, and
product segrigatlon. Thls training is
verified through the use of our procedure
qulz (DMF268).

DeKalb Metal Finlshlng utilizes Procedure

18 to ensure preservation of product.

DeKalb Metal Finishing utilizes Procedure

00, DMFJB4, and DMF253 to manage
facllity cleanliness. Procedure 09 and
DMF194 manage general plant
M
cleanllness while DMF253 relalea to
building maintenance.
 Special Process: Plating Process Assessment (General Facility Overview

Question Oueetlon Requlrements and Guldance

Number

Process control parameters shall be

monitored per frequencles specified in
Process Tables. Computer monitoring
equipment with alama and alam logs aatisfy
Are process control the verificatfon requlrement. A deslgnated floor
parametem monitored per person shall verlfy the process parameters, e.g.,
frequencles specified In by in)tia1Ing a strip chart or data Coq.
Process Tableg7

Aæ out of Are there documented reaction plans to

control/speclfiœ0on both out of control and out of tolerance
parameters revlewed and process parameters? Is there documented
2.12 reacted toi evidence that reactlon plens are followed2

2.13 Are In-Process / Final In-Process / Final Tegt Frequencles ahall be

Test Frequencies performed as speUfied In Process Tables. Refer
perfomed as speeified in to Process Tables.
Proœss Tables?
Test equipment shall be verified/calibrated per
applicable customer specific standard or per an
appllcable consensus standard, e.g., ASTM, SAE,
ISO, NIST, etc. Verifica#on/caIibra£on results
1s product test equipment ehell be Internally reviewed, approved and
2.14
verified?' documented.
Refer to Proœas Tables for frequency of checks.
 CQI-11
Special Process: Plafing System Assessment
Version 1 jssued B/07

g Process Assessment (General Facility Overview)

Objectlve Evldenee N/A Satlsfactor Not Satlafactory Heede lmme#late

y fictlon

end logged eje°'ronIcaIIy and are directly

linked la the control plans. this ensures that
changes made to lfie control plan ere
communicated to all affected parties

Cobol polnts are ldentlfled and reviewed

electronlcally. When a control polnt falls
outside the speUfied range, affected partles
are electronically rolfied and action is taken
to ensure the oontrol point Is regtored to
appropriate levels.

In-process and/or final testlng is done in

aœordance with the process tables.
The resullJng data ls stored
electronlcally,
DeKalb Metal Flnishlng ut#Izea gage
calibration software to log and monitor
calibrations and MSA studies. The
frequency of such testlng Is set per
gage and 1s deñved from past
calibratlon history. frequency of use, and
specified requlrements (I.e. customer,
CQI-11) .
 Section 3 - Zinc/ Zinc Alloy Plating Equipment

Question QU66tiO0 Requlrements and Guidance

Number
3.1 Does plating line have Refer to Procesu Table F for equipment
proper procesu control requirements.
equipment?
A system shall be used by the plating facility to
traak callbratlon dates of equipmenŁ This
system will typlcally be a computerized
tracking system or other notification system.
Are process and testing Test equipment shall be verified/calibrated per
equipment calibrations applicable customer specific standard or
32 consensus standard, e.g., ASTM, SAE, ISO,
and/or verification certified,
posted, and current2 NI3T, etc. Verification/calibration results shall
be internally reyiewed, approved and
documented.

Are barrels, racks, and Supplier shall have preventative maintenance

baskets maintained? system that is documented and implemented.
3.3

34 Are rectifiers maintained? Supplier shall have preventative maintenance

system that is documented and implemented.

For hydrogen embrittlement Uniformity survey must show that ovens were
relief ovens, are temperature tested both empty and with a dense load. PaM
uniformity surveys must come up to temperature within one Your of
3.5 performed yearlyY entering oven and meet temperature tolerance
specified by customer.

3.6 For hydrogen embrittlement Supplier shall have preventative maintenance

relief ovens, are system that is documented snd implemented.
thermocouples checked
and/or replaced quarterly?
 CQI-11
Special Procesu: Plating System Assessment
Vers|on 1 l4sued BIOS

Zinc/ Zinc Alloy Plating Equipment

Objective Evidence N/A Satlsfactory Not Needs lmmedlate

Satisfactory Actlon

DeKalb Metal Finishing utilizes gage

calibratlon software to log and
monitor calibrations and MSA
studies. The frequency of such
testing is set per gage and is
derived from past calibration
history, fiequency of use, and
specified requirements (i.e.
customer, CQI-11) .

Tooling is maintained on an on-

going basis as part of our
preventive maintenance system
(DMF253)

Rectifier are aerviced every 6 months X

as part of our preventive maintenance
system (DMF253)

X
 A+rtomolive Industry Acton Group

Section 4 - Decorative (Cu, Ni, Cr) Plating Equipm

Question Question Requirements and Guidance
Number

4,1 Does plating line have Refer to Process Table F for equipment
proper requirements.
process control equipment2 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 be verified/calibrated per
Are process and testing applicable customer specific standard or
equipment calibrations and/or consensus standard, e.g., ASTM, SAE, ISO, NIST,
4.2
verification certified, posted, etc.
and current2 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? Supplier shall have preventative maintenance

system that is documented and implemented.

4.4 Are rectifiers maintained? Supplier shall have preventative maintenance

system that is documented and implemented.
4.5 Are filters maintained2 Supplier shall have preventative maintenance
system that is documented and implemented.
4.6 Is all other applicable Supplier shall have preventative maintenance
equipment maintained? system that is documented and implemented.
4.7 For all thermocouples/ Supplier shall have preventative maintenance
thermometers are they system that is documented and implemented.
checked and/or replaced‘7
4.8 Are the process and Checks shall be documented. Each alarm shall
equipment alarm checks be reviewed independently for functionality if
being tested? applicable. Plater shall have a list of alarms
relevant to process.
 CQt•11
Special Process: Plating System assessment
Version 1 lasued 8/07

tive (Cu, Ni, Cr) Plating Equipment

Objective Evidence
Nx satisfactory Not Needs Immediate
Satisfactory Action
X

X
 DEKALB METAL FINISHING
Audit Criterion Requirements
Audit Data
ID code: Title:
Audit 8
PA000008 Product

Audit Category:
JA - Product Audits
Audit Purpose:
Internal Surveillance - Internal Surveillance
Audited Company:
Audit Company:
DEKALB METAL FINISHING

Lead Auditor:
Morris, Matt - mmorris
Audit Criterion Data
ID code: Name:

JA-11 Job Audit (Plating Lines)

Evaluation Revision:
Criteria:
JA - Job Audit 0
Conformity Level: Value.
P - Pass N/A

Audit Questions
ID code: Name: We
CQI 5.0 Job Audit - Finished Product Review 1

Conformity Level: Value:

P - Pass N/A
ID code:
Name: Wei9ht:
CQI 5.01 Quality Documents 4
Description:
Are Contract Reviews, APQP's, FMEA's, Control Plans, etc. performed by qualified individuals‘7

Audit Evidence:
All documentation listed is created and maintained by Top Management.
Conformity Level: Value:
P - Pass N/A

ID code: Name: Weig

CQI 5.02 Engineering Documents 4
Description:
Does the plater have the proper customer specifications for the part?
Audit Evidence:
Engineering Spec - DBL8451.15 was listed on the Job Setup Instruction and was available in lSOSystem D
Wolverine does not have any custoemr specific requirements
Weh . Ay ir4it . Mananqr ñ 1 0 - Mnrris Mall - 11/11/20fT9
B METAL FINISHING
ents

Audit type: 1st Party Scope

Period:

Type:
QA - Quality
Evaluation Type:
Qualitative
%C. AVLR: % CLR:
N/A N/A

Weight:
1

%C. AVLR. % CLR:

N/A N/A
Wei9ht:
4

fied individuals‘7

°/« C : AVLR: °/» CLR:

N/A N/A

Weight:
4
as available in lSOSystem Document.
 Audit Questions
Conformity Level: Value:
P - Pass N/A
ID code: Name:
CQI 5.03 Travelers
Description:
Is a shop traveler created to meet customer requirements?
Audit Evidence:
DMF250 and DMF trace tag had been created, and were attached to the box.
Conformity Level: Value: N/A
P - Pass
ID code: Name: Tracability
CQI 5.04
Description:
Is material identification (part numbers, lot numbers, contract numbers, etc.) maintained throughout the
process’7
Audit Evidence:
DMF250 and DMF trace tag had been created, and were used for identification throughout th
process.
Conformity Level: Value: N/A
P - Pass
ID code: Name: Receiving
CQI 5.05
Description:
Is there documented evidence of Receiving Inspection?
Audit Evidence:
The receiving section of DMF250 was completed and signed by Chris Davis
Conformity Level: Value: N/A
P - Pass

ID code: Name:
CQI 5.06 Part Setup
Description:
Are the Loading / Racking requirements identified?

Audit Evidence:
Loading / racking requirements were properly identified on the parts Job Setup Instruction. Tooling to be
54 with 4 pcs per bar and 3 bars per frame.
Conformity Level: Value:
P - Pass N/A
ID code: Name:
CQI 5.07 Process Monitoring
Description:
Is the proper procedure or process specification used? Refer to Process Tables for specific parameters. L
parameters that were verified in this audit in the spaces provided below.
Audit Evidence:
Reviewed operaters hourly line checks and found no reading outside allowable limits (7 blue 3 green). C
performed by Dory Cotrell.
Conformity Level: P - Pass Value: N/A
 °/> C : AVLR: °/» CLR:
N/A N/A
Weight:

e box.
°/» C : AVLR: °/< CLR:
N/A N/A
Weight:
1

, etc.) maintained throughout the plating

for identification throughout the coating

°» C : AVLR: °/» CLR:
N/A N/A
Weight: 1

avis
°/» C : AVLR: °/» CLR:
N/A N/A
Weight: 1

b Setup Instruction. Tooling to be used is B-

°/« C : AVLR: °/» CLR:

N/A N/A
Weight:
1

s Tables for specific parameters. List

w.
owable limits (7 blue 3 green). Checks were

°/< C : AVLR: °/» CLR:

N/A N/A
ni c
 Audit Questions
ID code: CQI Name:
5.08 Part Inspection
Description:
What are the product inspection requirements†
Audit Evidence:
These parts are to recieve 3 point thickness and visual inspection. All required inspections were performe
Ramona Didion. Point A = 2-17um (actual 3.84) Point B and C = 7-22um (Actual 9.74 and 10.0)
Conformity Level: Value:
P - Pass N/A
ID code: Name:
CQI 5.09 Process Signoff
Description:
Were appropriate are process steps signed off?
Audit Evidence:
DMF250 was signed by Ramonda Didion and Dory Cotrell at each individuals appropriate stages of proces
Conformity Level: Value:
P - Pass N/A
ID code: Name:
CQI 5.10 Part Inspection
Description:
Were all inspection steps, as documented in the control plan, performed?

Audit Evidence:
Reviewed Job Setup Instruction and Final Audit Log. All inspections were completed as documented.
Conformity Level: Value:
P - Pass N/A
ID code: Name:
CQI 5.11 Process Steps
Description:
Were steps/operations performed that were not documented in the control plan?
Audit Evidence:
Yes
Conformity Level: Value:
P - Pass N/A

ID code: Name:
CQI 5.12 Additional Process Steps
Description:
If additional steps not in the control plan were performed, were they authorized?
Audit Evidence:
There was no evidence of additional steps.
Conformity Level: Value: N/A
P - Pass
ID code: Name:
CQI 5.13 Lot Certifications
Description:
If the order was certified, did the certification accurately reflect the process performed?

Audit Questions
Audit Evidence:
Yes, cert was accurate vs inspection data.
Conformity Level: Value:
P - Pass N/A
ID code: CQI Name:
5.14 Lot Certifications
Description:
Was the certification signed by an authorized individual?

Audit Evidence:
Cert signed by Toni Smith
Conformity Level: Value:
P - Pass N/A
ID code: CQI Name:
5.15 Mixed Parts
Description:
Are the parts and containers free of foreign objects or contamination?
Audit Evidence:
Parts and containers (cardboard boxes) were dirty as shipped to us. We cleaned out the old brown paper
replaced with new.
Conformity Level: Value:
P - Pass N/A

ID code: CQI Name:

5.16 Packaging
Description:
Are packaging requirements identified?
Audit Evidence:
Reviewed Job Setup Instructions. Parts were bulk packed in layers per requirements.
Conformity Level: Value:
P - Pass N/A
ID code: Name:
CQI 5.17 Prevention of Mixed Parts
Description:
Are parts packaged to minimize mixed parts (parts packed over height of container)?
Audit Evidence:
Reviewed Job Setup Instructions. Parts were packaged as specified by the customer and in a manner to m
the risk of mixed parts.
Conformity Level: Value:
P - Pass N/A
ID code: Name:
CQI 5.18 Shipping Identification

Description:
Were the parts properly identified (for shipping)?
Audit Evidence:
A DMF trace tag was used to identifty the parts.
nñv?TGaa \ 7éh . A ‹ii* . Kasnsnor 0 n n . fianrriu n4sn d n /4 d /SinnQ
 Weight:
1

equired inspections were performed by

m (Actual 9.74 and 10.0)
°/» C : AVLR: °/» CLR:
N/A N/A
Weight:
1

duals appropriate stages of processing.

°/» C : AVLR: "f» CLR:
N/A N/A
Weight:
1

d?

e completed as documented.
°/» C : AVLR: °/» CLR:
N/A N/A
Weight:
1

trol plan?

°/» C : AVLR: °A CLR:

N/A N/A
Weight:
1

thorized?

°/» C • AVLR: °/« CLR:

N/A N/A
 Weight:
1

cess performed?

°/» C : AVLR: °/» CLR:

N/A N/A

Weight:
1

°/» C : AVLR: °/• CLR:

N/A N/A
Weight:

e cleaned out the old brown paper and

°/« C : AVLR: °/» CLR:

N/A N/A

Weight:
1

requirements.
°/» C : AVLR: °/< CLR:
N/A N/A
Weight:
1

of container)?

the customer and in a manner to minimize

°/> C : AVLR: °/» CLR:
N/A N/A
Weight:
1
 Audit Questions
Conformity Level: Value:
P - Pass N/A
ID code: Name:
CQI 5.19
Shipping Labels
Description:
Were the containers properly labeled (for shipping)?
Audit Evidence:
A DMF trace tag was used to identifty the container.
Conformity Level:
Value:
P - Pass
N/A

Legend
°/< c : Percentage Conformity
AYLR:
Average Value of Lower Level Requirements
°/» CLR: Percentage of Conformity to Lower Level Requirements
AVLR:
Average Value of High Level Requirements
°/» CHR:
Percentage of Conformity to High Level Requirements
N/A:
Not Applicable
 °/» C : AVLR: °/» CLR:
N/A N/A
Weight:

°/» C : AVLR: °/» CLR:

N/A N/A

rements

ts