Professional Documents
Culture Documents
Phone Number:
Fax Number:
Number of Heat Treat Employees at this Facility:
Internal (Captive) Heat Treater (Y/N):
Commercial Heat Treater (Y/N):
Date of Assessment:
Title:
Phone:
Email:
Auditors/Assessors:
Name:
Company:
Phone:
Email:
Question
Number
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
1.1
1.2
1.3
Question
Number
1.4
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
Question
Number
1.5
1.6
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
Question
Number
1.7
1.8
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
Question
Number
Question
1.9
1.10
1.11
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
Question
Number
Question
1.12
1.13
1.14
1.15
1.16
Is management providing
employee training for heat
treating?
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
Question
Number
Question
1.17
1.18
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
Question
Number
Question
1.19
1.20
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
Question
Number
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
2.1
2.2
2.3
2.4
10
Question
Number
2.5
2.6
2.7
2.8
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
11
Question
Number
2.9
2.10
2.11
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
12
Question
Number
2.12
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
2.13
2.14
2.15
2.16
13
Question
Number
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
Section 3 - Equipment
3.1
3.2
3.3
3.4
3.5
14
Question
Number
3.6
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
3.7
15
Question
Number
3.8
Question
3.9
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
16
Question
Number
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
3.10
3.11
17
Question
Number
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
3.13
3.14
18
Question
Number
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
3.16
3.17
3.18
3.19
3.20
19
Question
Number
3.21
Question
Objective Evidence
N/A
Satisfactory
Not
Satisfactory
Needs Immediate
Action
20
Question #
Related
HTSA Question #
4.1
1.2
1.3
1.4
1.17
4.2
1.5
4.3
4.4
4.5
4.6
Customer or Internal
Requirement
Actual Condition
(Objective Evidence)
Pass /
Fail / N/A
1.6
2.1
2.2
2.3
2.4
2.1
1.6
2.7
2.9
21
Question #
4.7
Related
HTSA Question #
Customer or Internal
Requirement
Actual Condition
(Objective Evidence)
Pass /
Fail / N/A
1.5
1.6
2.1
2.14
2.15
22
Question #
4.8
4.8.1
4.8.2
4.8.3
4.8.4
Related
HTSA Question #
Customer or Internal
Requirement
Actual Condition
(Objective Evidence)
Pass /
Fail / N/A
2.15
23
Question #
Related
HTSA Question #
1.2
1.4
4.11
1.2
1.4
1.6
4.12
1.2
1.4
1.6
1.11
1.17
4.13
1.11
4.15
4.16
Actual Condition
(Objective Evidence)
Pass /
Fail / N/A
1.4
2.2
2.3
2.14
4.10
4.14
Customer or Internal
Requirement
2.14
2.15
1.17
2.6
2.11
24
Question #
4.19
Packaging Requirements
Are packaging requirements
identified?
Are parts packaged to minimize
mixed parts (for example, parts
packed over height of container)?
Shipping Requirements
Were the parts properly identified?
4.20
4.17
4.18
Related
HTSA Question #
Customer or Internal
Requirement
Actual Condition
(Objective Evidence)
Pass /
Fail / N/A
2.9
2.9
2.3
2.9
2.3
2.9
25
1.0
A1.1
A1.2
Category/Process Steps
3.1
3.7
3.1
3.7
All furnaces, generators and quench systems shall have temperature indicating instruments.
Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen
probe, IR gas analyzer, etc.
A1.3
1.18
A program for furnace and generator burnout is required (applies to carbon bearing atmospheres).
A1.4
3.2
Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
A1.5
3.2
Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify
carbon potential in furnaces, shall be calibrated annually at a minimum.
A1.6
3.2
Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use.
A1.7
3.2
Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum.
A1.8
3.2
Oxygen probe controllers shall be calibrated quarterly (single-point or multi-point calibration) or semi-annual (multi-point
calibration only; single-point calibration not allowed).
A1.9
2.16
All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per
the applicable ASTM standard, ISO standard, JIS standard, or approved standard.
A1.10
2.16
Files for testing hardness shall be verified per the Customer requirement.
A1.11
3.2
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use (with distilled
water) and calibrated annually (per manufacturer's requirements) at a minimum.
2.0
A2.1
A2.3
3.2
3.3
3.2
3.3
3.2
3.3
A2.4
3.4
A2.2
PYROMETRY
Thermocouples and calibration of thermocouples shall conform to Section 3.1
Pyrometry Instrumentation and Calibration of instrumentation shall conform to Section 3.2
CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per Section 3.3
TUS shall be performed annually and after major rebuild per Section 3.4
Temperature uniformity tolerance for hardening furnaces shall be +/- 15 oC (or +/- 25oF). Temperature uniformity tolerance for
tempering furnaces shall be +/- 10oC (or +/- 20oF).
A2.5
3.5
OK / NOK / NA
Recorded temperature(s) for austentizing processes shall be controlled within +/- 10 oC (or +/- 15oF) of the set point as
evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower
tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
A2.6
3.5
Recorded temperature(s) for tempering and precipitation hardening processes shall be controlled within +/- 5 oC (or +/- 10oF) of
the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times
starting at the lower tolerance limit (as defined above).
A2.7
3.2
For
Continuous
Furnaces,
this requirement
to thecalibration
Qualified methods
Work Zone.
Infrared
pyrometers
shall be calibrated
annuallyapplies
using proper
or an approved manufacturer's procedure.
OK / NOK / NA
Batch
Furnace
Monitor primary temperature control instrument(s). Continuous recording with
sign-off every 2 hours or
each batch for processes
under 2 hours. Alarm
systems (if set per limits in
A2.5 and A2.6) satisfy the
sign-off requirement.
PROCESS MONITOR FREQUENCIES
A3.1
1.4
2.14
A3.2
1.4
2.14
3.7
A3.3
1.4
2.14
3.7
A3.4
1.4
2.14
3.7
3.8
A3.5
1.4
2.14
3.13
A3.6
1.4
2.12
Continuous
Atmosphere
Furnace
Generation
Continuous recording with Sign-off required
sign-off every 2 hours or
for each shift for
each lot for processes
generators.
under 2 hours). Alarm
systems (if set per limits in
A2.5 and A2.6) satisfy the
sign-off requirement
OK / NOK / NA
Generators shall
be continuously
monitored and
alarmed. Other
systems, such as
nitrogen-methanol
systems, may
either be
continuously
monitored and
alarmed, or signoff every 2 hours.
Daily
Quench Level
Agitation
A3.7
1.4
2.14
Each batch
A3.8
1.4
2.7
Each batch
A3.9
1.4
2.12
Quench Delay Time Quench delay time shall be based on the time
that the furnace door starts to open to the time
the load is at the bottom of the quench tank.
Each batch
A3.10
1.4
2.12
4.0
A4.1
1.4
2.15
Batch
Furnace
Each batch
Each load
Continuous
Furnace
Daily per furnace
OK / NOK / NA
A4.2
A4.3
A4.4
1.4
2.15
1.4
2.15
1.4
2.15
5.0
A5.1
A5.2
A5.3
A5.4
A5.5
2.12
3.14
2.12
3.14
2.12
3.14
2.12
3.14
2.12
3.14
A5.6
2.13
A5.7
2.11
Surface hardness
Each batch
Every 2 hours
Each batch
Every 4 hours
Each batch
Every 4 hours
Batch
Furnace
Continuous
Furnace
Daily
Semi-annually
Daily
Semi-annually
Semi-annually
Semi-annually
Semi-annually
Semi-annually
Daily
Semi-annually
Daily
Semi-annually
Semi-Annually
Semi-Annually
2x / week
2x / week
Daily
Each shift
Daily
Each shift
OK / NOK / NA
Item #
Related
HTSA
Question #
Category/Process Steps
1.0
B1.1
OK / NOK / NA
All furnaces, generators and quench systems shall have temperature indicating instruments.
B1.3
1.18
A program for furnace and generator burnout is required. Not required for retort gas nitriding.
B1.4
3.2
Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
B1.5
3.2
Dew pointers and gas analyzers, used to verify proper atmosphere in furnaces, shall be calibrated annually at a minimum.
B1.6
2.16
All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per the applicable ASTM
standard, ISO standard, JIS standard, or approved standard.
B1.7
2.16
Files for testing hardness shall be verified per the Customer requirement.
B1.8
3.2
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use (with distilled water) and calibrated
annually (per manufacturer's requirements) at a minimum.
B1.2
Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas
analyzer, etc. For salt bath, only temperature is required to be recorded.
2.0
OK / NOK / NA
PYROMETRY
3.2
3.3
3.2
3.3
B2.3
3.2
3.3
CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per Section 3.3
B2.4
3.4
TUS shall be performed annually and after major rebuild per Section 3.4.
B2.5
3.5
B2.1
B2.2
3.2
3.0
Infrared pyrometers shall be calibrated annually using proper calibration methods or an approved manufacturer's procedure.
PROCESS MONITOR FREQUENCIES
Batch
Furnace
Continuous recording with
sign-off every 2 hours or
each batch for processes
under 2 hours. Alarm
systems (if set per limits in
B2.5) satisfy the sign-off
requirement.
Continuous
Generators
Furnace
Continuous recording with Sign-off required
sign-off every 2 hours or
for each shift for
each lot for processes
generators.
under 2 hours). Alarm
systems (if set per limits in
B2.5) satisfy the sign-off
requirement
B3.1
1.4
2.14
B3.2
1.4
2.14
3.7
B3.3
1.4
2.14
3.7
3.8
B3.4
1.4
3.7
Every 4 hours
Salt Bath
Every 2 hours
& after any
change
Generators shall
be continuously
monitored and
alarmed. Other
systems, such as
nitrogen-methanol
systems, may
either be
continuously
monitored and
alarmed, or sign-off
every 2 hours.
Daily
Daily
N/A
OK / NOK / NA
Item #
Related
HTSA
Question #
Category/Process Steps
B3.5
1.4
3.7
B3.6
1.4
2.14
3.13
B3.7
1.4
2.12
B3.8
B3.9
B3.10
1.4
2.14
1.4
2.7
1.4
2.12
4.0
Quench Level
Agitation
Each batch
Daily
Daily
Each batch
Monitor load size or fixturing or loading rate as
applicable.
Quench Delay Time if applicable Each batch
Quench delay time shall be based on the time that the
furnace door starts to open to the time the load is at
the bottom of the quench tank.
IN-PROCESS/FINAL TEST FREQUENCIES
Each batch or
continuous
recording with
sign-off every
2 hours.
Alarm systems
satisfy the
sign-off
requirement.
Batch
Furnace
Each batch
Continuous
Furnace
Daily per furnace
Each batch
Each batch
Each batch
Generators
Salt Bath
B4.1
1.4
2.15
B4.2
1.4
2.15
1.4
2.15
1.4
2.15
Surface hardness
Each batch
Each batch
Each batch
Every 4 hours
Each batch
Each batch
Every 4 hours
Each batch
B4.3
B4.4
5.0
B5.1
B5.2
B5.3
B5.4
B5.5
2.12
3.14
2.12
3.14
2.12
3.14
2.12
3.14
2.12
3.14
B5.6
2.13
B5.7
2.11
Batch
Furnace
Continuous
Furnace*
OK / NOK / NA
Daily per
furnace
Generators
Salt Bath
Daily
Semi-annually
Daily
Semi-annually
Semi-annually
Semi-annually
Semi-annually
Semi-annually
Daily
Daily
Semi-annually
Semi-annually
Semi-Annual
Semi-Annual
2x / week
2x / week
2x / week
Daily
Each shift
Daily
Each shift
Daily
Each shift
Semi-annually
OK / NOK / NA
Item #
Related
HTSA
Question #
1.0
Category/Process Steps
C1.1
3.1
All furnaces and quench systems shall have temperature indicating instruments.
C1.2
3.1
Continuous strip charts and/or data loggers are required for temperature sensors.
C1.3
2.16
All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per
the applicable ASTM standard, ISO standard, JIS standard, or approved standard.
C1.4
3.2
Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
C1.5
3.2
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use (with distilled
water) and calibrated annually (per manufacturer's requirements) at a minimum.
2.0
C2.1
3.2
3.3
OK / NOK / NA
OK / NOK / NA
PYROMETRY
Thermocouples and calibration of thermocouples shall conform to Section 3.1.
C2.2
3.2
3.3
C2.3
3.2
3.3
CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per Section 3.3.
C2.4
3.4
Temperature Uniformity Survey (TUS) TUS frequency shall be quarterly and after major rebuild per Section 3.4.
Temperature Uniformity tolerance for solution and aging furnaces shall be +/- 5 oC (+/- 10oF).
Temperature Uniformity tolerance for annealing furnaces shall be +/- 15 oC (+/- 25oF)
Minimum and maximum temperature ranges shall be defined. Exception: If the operating range of the Qualified Work Zone is
equal to or less than 85oC (155oF) then only one temperature is required to be tested. The test temperature shall be within
the operating range of the Qualified Work Zone.
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
C2.5
3.5
For Solution Treating and Aging: Recorded temperature(s) shall be controlled within +/- 5C (or +/- 10F) of the set point as
evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower
tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone
C2.6
3.5
For Annealing Furnaces: Recorded temperature(s) shall be controlled within +/- 10C (or +/- 15F) of the set point as
evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower
tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone
C2.7
3.0
C3.1
3.2
1.4
2.14
Infrared pyrometers shall be calibrated annually using proper calibration methods or an approved manufacturer's procedure.
PROCESS MONITOR FREQUENCIES
Monitor primary temperature control instrument(s).
Batch Furnace
Continuous recording with
sign-off every 2 hours or
each batch for processes
under 2 hours. Alarm
systems (if set per limits in
C2.5 and C2.6) satisfy the
sign-off requirement.
Continuous Furnace
Continuous recording
with sign-off every 2
hours or each lot for
processes under 2
hours. Alarm systems (if
set per limits in C2.5 and
C2.6) satisfy the sign-off
requirement
OK / NOK / NA
Item #
Related
HTSA
Question #
C3.2
1.4
2.12
Category/Process Steps
Continuous recording
with sign-off every 2
hours or each lot for
processes under 2
hours. Alarm systems (if
set per acceptable limits)
satisfy the sign-off
requirement
Quench Level
Daily Verification
Agitation
C3.3
1.4
2.14
Each batch
C3.4
1.4
2.7
Each batch
C3.5
1.4
2.12
4.0
C4.1
1.4
2.15
5.0
C5.1
C5.2
C5.3
OK / NOK / NA
Each batch
Every 4 hours
OK / NOK / NA
Daily
Semi-annually
Daily
Semi-annually
Semi-annually
Semi-annually
Daily
Each shift
Daily
Each shift
Item #
Category/Process Steps
Related HTSA
Question #
1.0
D1.1
2.16
All hardness test equipment (for each scale used) shall be calibrated annually
minimum, and verified daily or prior to use, per the applicable ASTM standard,
ISO standard, JIS standard, or approved standard.
D1.2
2.16
Files for testing hardness shall be verified per the Customer requirement.
D1.3
3.2
2.0
D2.1
3.2
PYROMETRY
Infrared pyrometers shall be calibrated annually using proper calibration
methods or an approved manufacturer's procedure.
3.0
All process parameters shall be checked the beginning of every shift, tool change, or any equipment
repair. In absence of process parameter alarms, also check process parameters at end of shift or lot
(whichever is the greater frequency).
D3.1
1.4
2.12
OK / NOK / NA
Quench Temperature
Quench Level
D3.2
1.4
2.14
D3.3
1.4
2.14
3.16
OK / NOK / NA
Item #
Related HTSA
Question #
D3.4
1.4
2.12
4.0
Category/Process Steps
Temper Delay Time Each batch
The maximum delay time between
quenching and tempering shall be specified
on the control plan and monitored.
IN-PROCESS/FINAL TEST
FREQUENCIES PER COIL
Induction pattern length
OK / NOK / NA
D4.1
1.4
2.15
D4.2
1.4
2.15
D4.3
1.4
2.15
Surface hardness
D4.4
1.4
2.15
D4.5
1.4
2.15
Item #
Related HTSA
Question #
5.0
D5.1
Category/Process Steps
QUENCHANT AND SOLUTION TEST FREQUENCIES
2.12
3.14
2.12
3.14
2.12
3.14
D5.4
2.13
D5.5
2.11
D5.2
D5.3
Daily
Every four months (complete
replacement of the quench media
and cleaning of the quench tank
within four months satisfies this
requirement).
Semi-annually (complete
replacement of the quench media
and cleaning of the quench tank
within six months satisfies this
requirement)
Daily
Semi-annually (complete
replacement of the quench media
and cleaning of the quench tank
within six months satisfies this
requirement)
2x / week
Daily
Each shift
Category/Process Steps
All furnaces, generators and quench systems (where applicable) shall have temperature indicating instruments.
E1.3
3.2
Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
E1.4
3.2
Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to
verify carbon potential in furnaces, shall be calibrated annually at a minimum. This is applicable when used in
controlling carbon-bearing atmospheres.
E1.5
3.2
Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to
use. This is applicable when used in controlling carbon-bearing atmospheres.
E1.6
3.2
Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum.
This is applicable when used in controlling carbon-bearing atmospheres.
E1.7
3.2
Oxygen probe controllers shall be calibrated quarterly (single-point or multi-point calibration) or semi-annual (multipoint calibration only; single-point calibration not allowed). This is applicable when used in controlling carbonbearing atmospheres.
E1.8
2.16
All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior
to use, per the applicable ASTM standard, ISO standard, JIS standard, or approved standard.
E1.9
3.2
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use
(with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.
E1.2
Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew
point, oxygen probe, IR gas analyzer, etc.
OK / NOK / NA
Category/Process Steps
PYROMETRY
E2.1
3.2
3.3
E2.2
3.2
3.3
E2.3
3.2
3.3
CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per
Section 3.3.
E2.4
3.4
TUS shall be performed annually and after major rebuild per Section 3.4.
Temperature uniformity tolerance for furnaces operating at austenitizing temperatures shall be +/- 15 oC
(or +/- 25oF). Temperature uniformity tolerance for tempering furnaces shall be +/- 10 oC (or +/- 20oF).
E2.5
3.5
Recorded temperature(s) for austentizing processes shall be controlled within +/- 10 oC (or +/- 15oF) of the set point
as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times
starting at the lower tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
OK / NOK / NA
Category/Process Steps
PROCESS MONITOR
Batch Furnace
FREQUENCIES
Monitor primary temperature Continuous
control instrument(s).
recording with signoff every 2 hours or
each batch for
processes under 2
hours. Alarm
systems (if set per
limits in E2.5) satisfy
the sign-off
requirement.
Continuous
Generators
Furnace
Continuous
Sign-off required for each shift for
recording with
generators.
sign-off every 2
hours or each lot
for processes
under 2 hours).
Alarm systems (if
set per limits in
E2.5) satisfy the
sign-off
requirement.
E3.1
1.4
2.14
E3.2
1.4
2.14
3.7
Monitor generator
atmospheres
E3.3
1.4
2.14
3.7
Continuous
recording with signoff every 2 hours or
each batch for
processes under 2
hours. Alarm
systems (if set per
acceptable limits)
satisfy the sign-off
requirement.
Continuous
recording with
sign-off every 2
hours or each lot
for processes
under 2 hours.
Alarm systems (if
set per
acceptable limits)
satisfy the sign-off
requirement.
E3.4
1.4
2.14
3.7
3.8
Daily
Daily
E3.5
1.4
2.14
3.13
Daily
OK / NOK / NA
Category/Process Steps
E3.6
1.4
2.14
Each batch
E3.7
1.4
2.7
IN-PROCESS/FINAL TEST
FREQUENCIES
Microstructure shall be
checked at a minimum
magnification of 100x and,
400x or above 400x.
Microstructural visual
references shall be
available.
Each batch
Continuous
Furnace
Each production
run or each shift
at a minimum.
4.0
Batch Furnace
E4.1
1.4
2.15
E4.2
1.4
2.15
Each batch
Every 4 hours
E4.3
1.4
2.15
Each batch
Every 4 hours
Concentration
2x / week
2x / week
Concentration of cleaner
Daily
Daily
Temperature of solution
(required if temperature is
specified to be above
ambient temperature).
Each shift
Each shift
5.0
E5.1
2.13
E5.2
2.11
Batch Furnace
Continuous
Furnace
Washers
OK / NOK / NA
OK / NOK / NA
Category/Process Steps
PROCESS AND TEST EQUIPMENT REQUIREMENTS
F1.1
3.1
3.7
All furnaces and liquid quench systems shall have temperature indicating instruments.
F1.2
3.1
All gaseous quench systems shall have pressure indicators and fan operation indicators.
F1.3
3.1
3.7
Recording instruments are required for temperature and, hydrocarbon flow and pressure.
F1.4
3.2
Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
F1.5
3.2
Hydrogen sensors and carbon IR combustion analyzers used to verify carbon potential in furnaces, shall be calibrated annually
at a minimum.
F1.6
3.2
Verification of calibration of spectrometers and carbon IR combustion analyzers, shall be checked daily or prior to use.
F1.7
3.2
F1.8
2.16
All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per the
applicable ASTM standard, ISO standard, JIS standard, or approved standard.
F1.9
2.16
Files for testing hardness shall be verified per the Customer requirement.
F1.10
3.2
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use (with distilled
water) and certified annually per manufacturer's requirements at a minimum.
3.2
3.3
3.2
3.3
F2.3
3.2
3.3
CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per Section 3.3.
F2.4
3.4
TUS shall be performed annually and after major rebuild per Section 3.4.
F2.5
3.5
2.0
F2.1
F2.2
PYROMETRY
OK / NOK / NA
OK / NOK / NA
Temperature uniformity tolerance for hardening and tempering furnaces shall be +/- 10 C or +/- 20 F.
3.0
F3.1
F3.2
1.4
2.14
Recorded temperature(s) for austentizing and tempering processes shall be controlled within +/- 5 C or +/- 10 F of the set point
as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower
tolerance limit (as defined above).
PROCESS MONITOR FREQUENCIES
Monitor primary temperature control instrument(s). Continuous recording with sign-off every 2 hours or each batch for processes
under 2 hours. Alarm systems (if set per limits in F2.5) satisfy the sign-off requirement.
1.4
2.14
3.7
1.4
2.14
Monitor primary furnace atmosphere control(s) or hydrocarbon flows. Continuous recording with sign-off every 2 hours or each
batch for processes under 2 hours. Alarm systems (if set per acceptable limits) satisfy the sign-off requirement.
Monitor pressure in the carburizing and gas quenching process. Continuous recording with sign-off every 2 hours or each batch
for processes under 2 hours (carburizing process). Continuous recording with sign-off each batch (quenching process). Alarm
systems (if set per acceptable limits) satisfy the sign-off requirement.
F3.4
1.4
2.14
3.7
3.8
Verify primary atmosphere control method by back-up method by microstructural evaluation of parts or coupon, or carbon
analysis of shim stock or carbon bar. Verification shall be daily.
F3.5
1.2
2.7
Prior to production (APQP), the surface area of the parts shall be calculated and documented for each load configuration.
F3.3
OK / NOK / NA
Category/Process Steps
FREQUENCY
Continuous recording with alarm system is required.
Quench Level
Agitation
F3.7
1.4
2.12
F3.8
F3.9
1.4
2.12
4.0
Weekly
Temper Delay Time The maximum delay time between quenching and tempering
shall be specified on the control plan and monitored.
Each batch
IN-PROCESS/FINAL TEST
FREQUENCY
F4.1
1.4
2.15
Microstructure shall be checked at a minimum magnification of Daily per furnace (may rotate cells) or any time one of the
100x and, 400x or above 400x. Microstructural visual
process parameters is out of specification.
references shall be available.
F4.2
1.4
2.15
1.4
2.15
Surface hardness
Each batch
Daily per furnace (may rotate cells) or any time one of the
process parameters is out of specification.
1.4
2.15
Daily per furnace (may rotate cells) or any time one of the
process parameters is out of specification.
F4.3
F4.4
5.0
F5.1
F5.2
F5.3
F5.4
2.12
3.14
Daily
Semi-annually
2.12
3.14
2.12
3.14
Water Quenching
Suspended solids
Semi-annually
Oil Quenching
Water content, suspended solids, viscosity, cooling curve, total Semi-annually
acid, and flash point.
2.13
F5.5
FREQUENCY
2.11
2x / week
Washers
Concentration of cleaner
Daily
Temperature of solution (required if temperature is specified to Each shift
be above ambient temperature).
OK / NOK / NA
OK / NOK / NA
Item #
Related HTSA
Question #
1.0
G1.1
Category/Process Steps
PROCESS AND TEST EQUIPMENT REQUIREMENTS
3.1
3.7
All furnaces, generators and quench systems shall have temperature indicating instruments.
3.1
3.7
Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR
gas analyzer, etc.
G1.3
3.1
G1.4
1.18
A program for furnace and generator burnout is required (applies to carbon bearing atmospheres).
G1.5
3.2
Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential
in furnaces, shall be calibrated annually at a minimum (applies to carbon bearing atmospheres).
G1.6
3.2
Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use (applies to carbon
bearing atmospheres).
G1.7
3.2
Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum (applies to carbon
bearing atmospheres).
G1.8
3.2
Oxygen probe controllers shall be calibrated quarterly (single-point or multi-point calibration) or semi-annual (multi-point calibration only;
single-point calibration not allowed). This applies to carbon bearing atmospheres.
G1.9
2.16
All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per the
applicable ASTM standard, ISO standard, JIS standard, or approved standard.
G1.2
OK / NOK / NA
Item #
Related HTSA
Question #
Category/Process Steps
2.0
G2.1
G2.2
G2.3
G2.4
PYROMETRY
3.2
3.3
3.2
3.3
3.2
3.3
3.4
TUS shall be performed annually and after major rebuild per Section 3.4.
OK / NOK / NA
Temperature uniformity tolerance for hardening furnaces shall be +/- 15C (or +/- 25F). Temperature uniformity tolerance for tempering
furnaces shall be +/- 10C (or +/- 20F).
G2.5
3.5
Recorded temperature(s) for sintering processes shall be controlled within +/- 10C (or +/- 15F) of the set point for processes operating
less than 1000C (1830F) and +/- 20C (+/- 35F) for processes operating greater than 1000C (1830F) as evidenced by continuous
recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
3.0
G3.1
Batch
Furnace
Continuous recording with
sign-off every 2 hours or
each batch for processes
under 2 hours. Alarm
systems (if set per limits in
G2.5) satisfy the sign-off
requirement.
Continuous
Furnace
Continuous recording
with sign-off every 2
hours or each lot for
processes under 2
hours). Alarm systems (if
set per limits in G2.5)
satisfy the sign-off
requirement
Atmosphere Generation
One of the three options is
required.
(1) Record temperature 2x
per shift or after any
change.
(2) Continuously record
temperature and sign-off 2x
per shift or after any
change.
(3) Alarm system on
temperature controller.
G3.2
OK / NOK / NA
Item #
G3.3
Related HTSA
Question #
1.4
Monitor primary furnace atmosphere control(s)
2.14
Flow rates.
3.7
Category/Process Steps
Batch processes are in
vacuum furnaces:
G3.4
1.4
2.14
3.7
3.8
G3.6
1.4
2.12
Daily
G3.7
1.4
2.12
G3.8
1.4
2.14
Each batch
G3.9
1.4
2.7
Each batch
Item #
G3.10
Related HTSA
Category/Process Steps
Question #
1.4
Quench Delay Time Each batch
Not applicable for belt
2.12
Quench delay time shall be based on the time that the
furnaces.
furnace door starts to open to the time the load is at
the bottom of the quench tank (oil) or the start of the
gas pressure quenching (gas quench).
Item #
Related HTSA
Question #
4.0
G4.1
G4.2
G4.3
G4.4
Category/Process Steps
1.4
2.15
1.4
2.15
OK / NOK / NA
Each Lot
Each Lot
Apparent hardness
Each batch
Every 4 hours
Each batch
Every 4 hours
Category/Process Steps
PROCESS AND TEST EQUIPMENT REQUIREMENTS
OK / NOK / NA
H1.1
3.1
3.7
All vessels shall have temperature, flow meters, vacuum gages, and gas flow indicating instruments.
H1.2
3.1
3.7
Data loggers and/or Recording instruments are required for temperature, pressure, amps and volts. Amps and volts are referance only. Frequency is per
customer and control plan
H1.3
1.18
H1.4
3.2
H1.5
3.2
Gas ratios controller / meters shall be calibrated / verified as recommended by the manufacturer. As an option gas composition may be analyzed using gas
mixture analyzer semi- annually and calibrated as recommended by the manufacturer.
H1.6
2.16
All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per the applicable ASTM standard,
ISO standard, JIS standard, or approved standard.
H1.7
2.16
Files for testing hardness, if used, shall be verified per the Customer requirement.
2.0
H2.1
H2.2
3.2
3.3
3.2
3.3
PYROMETRY
Thermocouples and calibration of thermocouples shall conform to Section 3.1.
OK / NOK / NA
H2.3
3.2
3.3
Protection Tubes for thermocouples in the vessels, if used, shall be visually checked for each batch.
H2.4
3.4
Temperature Uniformity Survey (TUS) and Systems Accuracy Test (SAT) are not required.
In lieu of TUS & SAT, Temperature ranges shall established during preproduction testing usining multiple thermocouples representing the work zone and
confirmed in the capability study and documented in the Control Plan for each part.
H2.5
3.5
Temperature shall be controlled with thermocouples in the load for each batch placed as practical to represent the extremes of the load (max and min
temperatures) as evidenced by recording.
H2.6
3.2
Infrared pyrometers shall be calibrated annually using proper calibration methods or an approved manufacturer's procedure.
H3.1
1.4
2.14
Each batch or recording per see H1.2 above with sign-off every 2
hours. Alarm systems satisfy the sign-off requirement. Control
plan to include the lose of a thermocouple during the run and alarm
settings. Alarms are to be checked quarterly and alarms during the
cycle are to be documented.
H3.2
1.4
2.14
3.7
Each batch or recording per see H1.2 above with sign-off every 2
hours. Alarm systems satisfy the sign-off requirement. Control
plan to include the alarm setting. Alarms are to be checked quarterly
and alarms during the cycle are to be documented.
H3.3
1.4
2.11
2.12
Pump down of 75 microns per hour or less and leak up of 90 microns per hour or less
are required prior to initiating the cycle
Each Batch
H3.5
1.4
2.14
1.4
2.7
Each batch
Each batch
H4.1
1.4
2.15
Each Batch
H4.2
1.4
2.15
1.4
2.15
1.4
2.15
Surface hardness
Each Batch
Each Batch
Each Batch
2.13
3.0
H3.6
4.0
FREQUENCY
IN-PROCESS/FINAL TESTS
H4.3
H4.4
5.0
SOLUTION TESTS
H5.1
H5.2
58
2.11
Washers
Concentration of cleaner
OK / NOK / NA
FREQUENCY
OK / NOK / NA
FREQUENCY
OK / NOK / NA
H5.2
2.11
59