This manual provides guidelines for evaluating the Heat-treatment systems of a heat-treat manufacturing facility.
Distributed by Global Materials & Fastener Standards. For content and technical questions please contact: R.F. Buelow (rbuelow@ford.com) or Y. Kim (ykim1@ford.com)
Manufacturing Standard W-HTX is available within Ford Motor Company at www.ctis.ford.com/gms/secure1/data/9200398.pdf. Customers outside of Ford need to contact their Ford Standards Provider.
SECTION I - INTRODUCTION
This documentation has been prepared to achieve Ford's mission of never ending improvement at all Ford plants having Heat Treat operations and all heat treators, Tier 1 and Tier 2, It has been organized in a manner that it will be used as a tool to: Define the requirements for the heat treat process and the heat treatment processor. Assess heat treatment process controls, process capability and dedication to never-ending improvement using Statistical Process Control. Provide the opportunity to streamline auditing procedures for heat treat processes and heat treatment processor.
The following section will be used in defining the usage and application of the Heat Treat System Survey.
SECTION II - APPLICATION
Application includes: Heat Treat facilities found within a Ford Motor Company manufacturing facility. Where the first tier heat treater to Ford Motor is performing a heat treat function, the Heat Treat System Survey must be conducted in conjunction with QS-9000 System Survey. Where a commercial heat treat source is a direct supplier of heat treat services to any Ford manufacturing or assembly plant, this survey will be used. If a heat treat source is a sub-supplier (e.g. second tier, third tier) to a Ford Manufacturing or Assembly Operation, then the first tier supplier is responsible for conducting the Heat Treat Survey and submitting the survey to the responsible STA Engineer for review, as appropriate.
Having collected and charted sufficient data to permit control limits to be established, any subsequent "out of control" condition will become immediately apparent. In certain instances, no action is possible to improve the variability of a supplied material, but charting methods can still provide useful information by highlighting the need for early correction to subsequent processing.
No attempt should be made to chart all of these and other related parameters because a number of these parameters may be interdependent and results will be difficult to interpret. Tracking these parameters may be by MA & MR and I & MR or other appropriate SPC methods. PRODUCT TESTING Assuming that the control charting of selected process characteristics has shown process stability and a reduction in variability, then a proper characteristic to gain process knowledge has been selected. The testing of the finished product is an "Indicator" by which the effect of process improvements can be monitored. In selecting properties to be tested, attention should be given to the prime requirement of the customer. Correlation studies should be conducted where tests may be repeated by the customer. The choice of properties for test will therefore rest with the 1st tier and/or Heat Treater and the end customer.
Moving average and moving range charts can prove extremely useful on processes where infrequent or limited process data is available. The selection of which technique to use depends entirely on the type of process being monitored - an individuals chart will react positively towards sudden short term process fluctuations whereas a moving average chart is more sensitive to smaller long term changes in process performance. Checking frequencies and nominal subgroup sizes must be suited to process requirements and meet the requirements of W-HTX. Sample charts follow:
2.1 2.4%
Remarks
--------------
---------------
X = 2.23
R = 0.117
Shift Time
____ ___ ____ ____
0.121
UCLX = X + A2 R = 2.35 2.11 Contents Sample Size -n
2 3 4 5
Check No. 1
X1 X2 X3 X4 X5 X
--------------
LCLX = X + D3 R = _________
____ ___
2
2.25
10
11 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
____
____
LCLX = X + A2 R = 2.20 2.25 2.30 2.25 2.35 2.20 2.10 2.15 2.15 2.20 2.10 2.35 2.25 2.25 2.10 2.25 2.20 2.40 2.35 2.30 2.30 2.20 2.25 2.25 2.15
UCLX = X + D3 R =
0.30
A2
1.880 1.023 0.729 0.677
D2
0 0 0 0
D3
3.288 2.674 2.282 2.114
X
---------------
R
APC
0.05 0.1
0.05 0.1
0.25
0.25 0.1
0.2
0.1
0.05 0.1
0.05 0.5
0.1
2.1 2.4%
Remarks
--------------
---------------
X = 2.23
R = 0.117 0.121
____
UCLX = X + A2 R = ___________
2
2.25
10
11 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
LCLX = X + D3 R = ___________
____ ___
____
____
LCLX = X + A2 R = ___________ 2.20 2.25 2.30 2.25 2.35 2.20 2.10 2.15 2.15 2.20 2.10 2.35 2.25 2.25 2.10 2.25 2.20 2.40 2.35 2.30 2.30 2.20 2.25 2.25 2.15 Sample Size -n
2 3 4
UCLX = X + D3 R =
0.30
Contents
A2
1.880 1.023 0.729 0.677
D2
0 0 0 0
D3
3.288 2.674 2.282 2.114
X
---------------
R
APC
0.05 0.1
0.05 0.1
0.15 0.25
0.1
0.15
0.2
0.1
0.05 0.1
0.05
0.5
0.1
High
WHEN NORMALIZING PROCESS High Variation in steel chemistry (e.g., % carbon at the high end of the specification). Improper austenizing furnace atmosphere (i.e., high carbon potential). Wrong process (i.e., parts quenched).
WHEN CARBURIZING AND CARBONITRIDING Low High Variation in steel chemistry (e.g., % carbon at the low end of the specification and/or insufficient alloying elements). Surface decarburization in the austenizing furnace (i.e., low carbon potential). Retained austenite because of high carbon potential. Delay quench (i.e., excessive hold time between austenizing furnace and quench). Insufficient quench time causing part to temper, due to residual heat in the part. Quench media temperature (high). Quench media agitation (insufficient). Tempering furnace temperature (high). Variation in steel chemistry (e.g., % carbon at the high end of the specification and/or insufficient alloying elements). Improper austenizing furnace atmosphere (i.e., high carbon potential). Quench media temperature (low). Tempering furnace temperature (low). Insufficient tempering (i.e., time/temperature relationship).
EFFECTIVE CASE DEPTH Low Variation in steel chemistry (i.e., % carbon low). Austenizing furnace zone temperature (low). Austenizing furnace cycle time (fast or short). Improper austenizing furnace atmosphere (i.e., low carbon potential). WHEN INDUCTION AND/OR FLAME HARDENING Low case depth High current frequency. Cycle time (short). High case depth Low current frequency. Cycle time. CAUSAL FACTORS FOR BRITTLENESS WHEN TEMPERING Insufficient time. Insufficient temperature. WHEN AUSTEMPERING Insufficient time in salt (to insure transformation). Insufficient salt temperature (to insure transformation). WHEN CARBURIZING/CARBONITRIDING Excessive carbon (e.g., intergranular carbide formation). Inadequate transformation during quenching.
Furnace
Temperature Time Zones Total time Maintenance** Belt Speed Atmosphere
Quench*
Cooling Rate Still Air
Mass Distribution Furn. Press. Circu. Fan Ammonia Nitrogen Prior Microstructure Flow Rate Product Cooling Rate# Exothermic Gas
Forced Air
Experienced
Heats
Materials
Note:
Operator
Loading
* For normalizing only # Furnace Cooling for the Annealing Process only ** Maintenance = Reliability of the Process Monitoring Equipment
Tooling
Induction Coil Design Wear Material Leakage Runout Part Conf. Energy Monitor Calibration Coil Set Up Instruction
Inductor
Process Controller Ircon
Quench
Temperature Temperature Time Maintenance**
Maintenance**
Delayed Quench
Case Hardening
Incoming Specification Over Hardenability Charge Contamination Continuous Batch Under Process Training Procedure Heats Overload Special Fixturing Special Fixturing Overload
Experienced
Materials
Note:
Operator
Loading
Furnace
Temperature Time Zones Time Total time Belt Speed Atmosphere Maintenance** Soak Time Belt Speed
Quench
Temperature Time
Temper
Temperature Material Handling Maintenance** Prior Microstructure
Delayed Quench Carbon Poten Furn.Press Circu. Fan Air Ammonia Prior Microstructure Part Design Chemistry Clean/Dry Steel Grain Size Under Process Training Procedure Heats Overload Special Fixturing Special Fixturing Overload Flow Rate Endo Natural Gas Media Pumps/Propellers Power Usage Flow Rate Circu. Fan
Properties
Materials
Note: * For Carbo-Nitriding Process only
Operator
Loading
Develop Control Plans for all of the causes identified, in the Cause & Effect and PFMEA documents for the failure modes identified in the reaction plan. Refer to page 18 for a typical Dimensional Control Plan.
2 Process Sheet Leading Details 3 Temp controls with verification by Operating personnel, Process Sheets 3 Oxygen probes & visual by operating personnel
1 10 None
Carbonitriding Temperature set to high or low Excess Carburizing temperature from thermocouple or protection tube fail Carbonitriding Temperature set to high or low Excess Carburizing temperature from thermocouple or protection tube fail Carbonitriding Temperature set to high or low Excess Carburizing temperature from thermocouple or protection tube fail Carbon potential of atmosphere to low (High Dew Pt.) Carbon potential of atmosphere to low (High Dew Pt.) Carbonitriding Temperature set to high or low
2 30 annual review
annual review
5 2 2 20
5 2 2 20
3 Temp controls with verification by Operating personnel, Process Sheets 3 Oxygen probes & visual by operating personnel
8 2 2 32
8 2 2 32
3 Temp controls with verification by Operating personnel, Process Sheets 3 Oxygen probes & visual by operating personnel
8 2 2 32
8 2 2 32
3 Oxygen probes & Dew Pt. Gage 3 Oxygen probes & Dew Pt. Gage
1 15 None
2 30 annual review
annual review
5 2 2 20
c u r
6 None
Airpathway is plugged Broken motor/pump belt Mixer motor failure Mixer pump failure Lack of burnout, old tubes Excess Carburizing temperture from thermocouple or protection tube fail Blower motor failure
2 12 1 8
1 1 1
4 8 6
2 Visual
1 12
1 Visual
Dualpro is unresponsive, High or low dew pt. electricity and gas continue to run through generator
Soot buildup, causing poor flow across catalyst Catalyst was oxidized preventing surface contact Dualpro failure or asco valve on flow meter has failed Electrical Failure
PROGRAM PLANT PART NAME PART NO. B/P DATE DEPT NO. OP. - STA. NO S.T. NO.
. . . . . . .
REVISIONS CHG NO. 1 2 3 4 5 6 7 8 9 DESCRIPTION 10/31/97 CHANGE FREQUENCY ON HARDNESS, CD. PARAMETER SCREEN 10/31/97 CHANGE FREQUENCY TO 1 SHIFT ON QUENCH CONCENTRATION 11/27/97 CHANGES PER AUDIT COMMENTS 10/31/98 CHANGES PER W-HTX 09/20/99 UPDATE GAGE R&R CMG By CB CB EZ CB CB Approved Effective RESPONSIBILITY By Date CODES EZ 10/31/94 O = OPERATOR T = MFG TECM EZ 10/31/94 L = LAYOUT Q = QUALITY TECH EZ 11/27/94 M = MAINTENANCE EZ 11/06/95 C = CHEM/MET LAB EZ 11/20/96 G = GAGE REPAIR U = LIGHT UP RELATED INSTRUCTIONS S = SETUP O = OPERATOR M = MAINTENANCE L = LUBRICATION G = GAGING/CALIBRATION D= OPERATION DETAIL
01/11/91 40
1 OF 1 11/03/93 12/31/98
ID
Description
Spec
Typ e IP
PRODUCT CONTROL ITEM Capability Control Method (Record) P/C F/Cpk Date p NA NA NA NA CHECK SHEET
R E S
Gage Description
V / R&R A %
Check Item
Aff IDs
Check Method
RI R EM E LS S
92A
PATTERN LOCATION
W-HTX
QUENCH PRESSURE
92A-C,B
NA
AUTO REJECT
100%
PRESSURE SWITCH
92B
MICROSTRUCTURE
W-HTX
IP
NA NA
NA NA
CHECK SHEET
92 C
85.5 HR15N
ES
S.T
92 D
HARDNESS TESTER VERIFICATION HR 15N EFFECTIVE CASE DEPTH SPLINE TO 83.0 HR 15N CRITICAL PARAMETER TREND REVIEW ENERGY/QUENCH FLOW QUENCH TEMPERATURE ROTATION SPEED
IP W-HTX
NA NA
NA NA
TREND CHART
T,S
C ONCE/WEEK & DELIVER TO MET LAB AFTER COIL FOR CHANGE OR METALLURGICAL POWER EVALUATION CHANGE T METALLURGICAL AT START UP, INSPECTION SET UP, AND STATION EVERY 4 T HOURS HARDNESS TESTER ONCE/SHIFT T METALLURGICAL INSPECTION STATION
TCP
100%
AUTOMATIC TRENDING/TC P
V 8.6 QUENCH CONCEN. 92A-C,E 5-1.5% RUN CHART ONCE/SHIF (RECORD ADJ. T ON CHART LOG) & AFTER CHANGE V
T REFRACTOMETER
92E
NA NA
NA NA
92F
AT START UP, SET UP , AND EVERY 4 HOURS EVERY 4 HOURS AND CHANGE
NA
TCP SCREEN
T,S
NA NA
NA NA
REF IP 92E
5 to 6
7 to 8
9 to 10
7 to 8 9 to 10
2. Are Control Plans and Process Failure Mode and Effects Analyses (PFMEA) used as a basis for establishing quality programs for heat treat processes? (QS-9000, Element 4.2 and 4.9) (W-HTX, 1.5) Evaluate heat treater's use of a documented method to develop manufacturing quality plans for heat treat processes by reviewing items such as: Cause and effect diagrams. Process flow diagrams, Design/Process FMEA's, Control Plans It is essential that the documentation is developed using information such as: material specifications, material hardenability range, furnace loading, temperature control (austenitizing/tempering furnaces and quench systems), atmosphere control for generators and furnaces, flow rates, discharge mechanisms to the quench system, quenchant properties and conditions, etc. Does the heat treater use the above mentioned analysis process to determine significant characteristics and process parameters? Review the heat treater's methodology to resolve potential problem areas in the process. Is the customer/end user of the heat treated product brought into the quality planning process? Has the customer approved the Control Plan(s) (e.g., First tier supplier for second tier supplier)?
3 to 4
5 to 6 7 to 8
9 to 10
3. Does the heat treater have available and use a procedure for reviewing part design and heat treat process changes prior to implementation? (QS-9000, Elements 4.4 and 4.16) The goal is an effective, documented process for obtaining customer approval of heat treat process changes. While many drawings and engineering specifications (ES) require such communication, the heat treater must have an appropriate system to bring this about. The heat treater must effectively notify all affected activities both internally (Manufacturing, Engineering, Production, Quality, Maintenance) and externally (Product Engineering, STA, Purchasing, Receiving Locations). Are FMEAs and Control Plans reviewed and updated as part of the procedure? Is customer approval obtained prior to implementing changes? When product drawing has a note stating that "change in design, composition, heat treat location, or process from parts previously approved for part production" the heat treater will be required to obtain prior engineering approval (Supplier Request for Engineering Approval Form 1638). (http:\\wwwwise.ford.com/html/forms.html) Internal Ford plant use of WERS Alert System
Is there a procedure for updating operator instructions and visual aids for process and product changes?
3 to 4
5 to 6
7 to 8
10
Evaluate the heat treater's reaction to out-of-control conditions. Is the reaction as specified in the Control Plan? What is the role of the operator? Who is responsible for reacting? Are root causes determined? Are concerns permanently resolved or do they "recur"? Review appropriate records. Is there an internal review of the charts to verify accuracy and proper analysis?
Evaluate heat treater's application of SPC, based on the evidence of the control charts, process logs and other appropriate documentation.
3 to 4
5 to 6
7 to 8
9 to 10
Preliminary statistical studies are early, short term evaluation of a process to gain information on both the variability of the process and its potential for producing products meeting specifications. The data must be analyzed using control charts or similar time sequence methods so that changes occurring during the production run will be evident. While the short duration of typical process capability studies makes this a very limited test for stability, any instability that does occur (e.g., quench hardness, cracks, distortion or shifts in values of characteristics or parameters) must be noted, understood, and reconciled to the satisfaction of all parties. For For certain heat treat characteristics such as hardness, microstructure, case depth, etc., the following SPC method will be considered acceptable: continuous process: use individual moving range chart Select sub-group sample size of 4 or 5 taken over time of the entire production run. For the individual chart, print specification can be used for upper and lower control limits. However for the range (r) chart the upper control limits must be developed using D4*R(average). The study will be considered stable and capable if all individual readings fall within B/P specification limits, for each sub-group, and no points fall outside the Upper Control Limit of the range. For capability indices data can be presented as 100 %, when all points in the range chart fall within the Upper Control Limit. Reported percentage should be reduced for number of points out of control.
Note: For other appropriate methods for charting please refer to Section IV. For batch process: use histogram analysis Randomly select minimum samples of 30 pieces (for each batch load), from different layers or location whichever best represents potential process concerns, from an entire Product Verification Run and measure the characteristics. A histogram must be developed and analyzed if the universe of the individual values is normally distributed. The study will be judged acceptable if all samples meet print specification.
When the Ppk requirement of QS-9000 is not met process improvement actions and repetition of the preliminary studies are required. If Ppk requirements cannot be met then containment actions must be provided in the Control Plan. Note: The index Ppk is used to distinguish preliminary statistical results from longer term process capability index, Cpk.
3 to 4
5 to 6
9 10
Note:
It is mandatory that statistical control (stability) be demonstrated before any statement of capability (Cp/Cpk) can be calculated. Is the potential for "over control" recognized? Do all personnel understand the significance of various signals from control charts?
Capability applies only to characteristics that can be evaluated using variable data. For characteristics that can only be evaluated with the attributes data, efforts shall be directed towards achieving stability and then reducing the absolute level of concerns. The method of calculating the standard deviation for capability evaluations shall be reviewed and verified to be statistically appropriate. Are unstable and non-capable processes given high priority for process improvement? Are there documented action plans and indications of improvement on such processes?
Processes that have historically (30 days or more) been stable and capable and which have recently gone out-ofcontrol will be considered as stable and capable, provided that appropriate, documented containment actions have been taken and a rigorous effort to eliminate the special cause is in progress.
3 to 6
9 to 10
7. Does the heat treater have a definite program to bring about continual improvement in quality and productivity? (QS-9000, Section II)(W-HTX, 1.1) Improvement plans must be detailed and specific, e.g., improve the first-run capability of specific operations by evaluating different process parameters (temperatures, pressure, atmosphere, cycle time, furnace loading, etc.). Describe the program. Indicate how responsibility is assigned and how progress is evaluated. Include the statistical methods and other tools used to promote continuous improvement. List any methods for which documented evidence is available. Evaluate the scheduled preventive maintenance program for the heat treat process and measurement system. Review the heat treater's Quality/Business Operating System (QOS). Evaluate the significance of the selected indicators to the philosophy of continuos improvement.
Note: Quality/Business operating indicators should be jointly selected between the Heat Treater, first tier heat-treater and the Ford Powertrain Plant.
3 to 4
5 to 6
7 to 8
9 to 10
8. Does the heat treater have an effective system for ensuring the quality of incoming products (such as gases, quench oils, salts, etc.) and services (instrumentation, furnace calibration, metallurgical and physical analysis etc.) How is SPC encouraged at Tier 1 and Tier 2 suppliers? (QS-9000, Element 4.10 and 4.11) The acceptable methods for controlling incoming quality are heat treater implementation of SPC and receiving inspection. The supplier must ensure that its Tier 1 and Tier 2 heat treaters have quality systems incorporating acceptable quality principles. Assess the adequacy of the heat treaters control on the quality of the service it receives. Describe the heat treaters audit program, in detail, to ensure the quality of the services it receives. Does the heat treater have a formal STA program to audit its material and service suppliers.
5 to 6
7 8
9 to 10
Assess heat treater's chemical and metallurgical laboratory capability to perform the minimum product process control functions. It may be necessary for a heat treater to have the capability to perform metallographic analysis, micro and macro hardness testing, carbon analysis, etc.
Note:
The type of heat treat processes performed in the heat treater's plant will have some effect on the types of controls chosen by the heat treater. A basic principle is that a control should be located as close as possible (both in space and time) to the process being controlled. Identification of inspected products by time, shift, date and/or operator is considered a good practice and should be followed.
9 to 10
10. Are written procedures defining quality-related functions available (i.e., a quality manual)? (QS-9000, Element 4.2; Section III, Ford Specific)(W-HTX, 1.3, 1.4, 1.5, 1.6, 1.7, 2.1.4, 2.1.6) Procedures should be available for the following quality related functions when these functions exist in the heat treater's plant General Operations Feasibility Review and Quality Planning (new product/process launch procedure) Process Potential and Capability Studies Receiving Inspection Ongoing SPC First-piece Inspection as dictated by Heat Treat Process (e.g., following quench and temper operations) In-process Auditing(Process and Product Parameters) Final Inspection Status Identification (tagging) Heat Treat Process Specification Documentation Ongoing Process parameter Monitoring (e.g., cycle times, gas flow rates, temperatures, loading rates, pressures, etc.) Thermocouple/Protection Tube Checking and Replacement Emergency Start-up and Shutdown Lot Traceability (customers material heat code, etc.) ES Testing Documentation and Response to Failures Process Monitors/Test Equipment Calibration and Maintenance Inspection/Test Equipment (Measurement systems) Variation Studies Purchased Product and Service Analysis (Audit) Returned Product Analysis (TOPS) Drawing and Change Control (including deviations) Records Retention (breakdown, process revision, etc.) Reprocess Authorization Internal Auditing of Procedure Furnace Atmosphere Purging (W-HTX, 2.1.6) Quench Solution Maintenance Bond Crib/Quarantine Area Furnace/Generator Burnout Laboratory Test Instruction Sheets Other Routine Functions Affecting Product Quality
Are these procedures appropriate to and adequate for the heat treater's operations? Are the procedures implemented as written? Is there a review process to verify implementation?
The number of procedures and the amount of detail required will vary according to the size of the heat treater's operations and the complexity of the process involved. Provide descriptive commentary and rationale for the determination of adequacy or inadequacy. Is there an adequate procedure for reacting to ES, product qualification, and test failures?
11. Are written process monitoring and control instructions available for incoming, in process, laboratory, dimensional inspection and outgoing auditing? (QS-9000, Element 4.9, 4.10, 4.18, 4.20)(W-HTX, 2.4, 2.5, 2.6, 2.6.2, 3.4, 3.5, 3.6, 4.0, and 5.0) Process monitoring and control instructions (including instructions for specialized process controllers and test equipment) must be available in written form. If not, a zero must be assigned for this question. These instructions may be combined with process sheets or data log sheets so long as all required information is included. Are all special parameters included, particularly those affecting function and durability?
Review part drawings, Product/Process Control Plans, and any other available documents indicating special characteristics. If these are inadequate or unavailable, contact Product Engineering and the consumer plant Manufacturing Engineering/Quality activity for this information. Are special characteristics and related operations identified? Are there instructions available for ES and ES-M requirements? Are sample sizes and frequencies adequate? (W-HTX, 4.0, 5.0)
The sampling plan must be developed to address the important source of variation to allow assessment of stability and capability. For SPC with variables data, an initial sample size of five units per hour is suggested unless some other sample size/frequency is specified in a customer approved product/process control plan. After statistical control and capability are demonstrated, gradual reductions of either sample size or frequency are often appropriate. For attribute checks, either product qualification or 100% inspection is required with appropriate control charting. Metallurgical Properties for Ford Parts, must be checked at least once for every material lot change. For case depth, microstructure and hardness refer to Question 5 paragraph 2 and section VI of this Heat Treat System Survey guide.
An appropriate control chart should be used for each significant checking or inspection operation as specified by the Product/Process Control Plan. For variables data (to be obtained wherever feasible); X-MR, X-s, or median charts may be used. For either product qualification or 100% inspection, the appropriate attributes chart (p, np, c or u) should be used. Refer to section 4 for additional details.
3 to 4
5 to 6 7 to 8 9
10
12. Are appropriate process monitors, thermocouple and inspection/test equipment available to facilitate process control? Does the heat treater have an effective equipment calibration and measurement program. (QS-9000, Element 4.11)(W-HTX, 2.1.1, 2.6, 3.1.1, 3.6) Are process inspection and test equipment available to provide process operators with variables data whenever such data can feasibly be obtained? Are all special process parameters/product features being accurately measured? Are inspection/test equipment and personnel appropriately located throughout the heat treat operations? Does the heat treater have event recorders or equivalent to provide a record of furnace operations? Are inspection/test equipment and process monitoring equipment variation studies used to evaluate these devices for stability and capability?
Each process operator should have, or have immediate access to, inspection and test equipment providing relevant data on the product characteristics/process parameters under the operator's control. Any chemical/metallurgical laboratory equipment needed to conduct ES and ES-M tests should be available. Are over temperature and under temperature (when applicable) controls in place and being utilized on all zones of furnaces, quench systems and tempering operations? (W-HTX, 2.1.1) Is non-contact infrared thermometry being used (in addition to conventional thermocouple) to monitor high heat zones of furnaces or individual induction/flame hardening part temperatures. (W-HTX, 2.1.1) Are heat monitor/control instruments properly placed to avoid extremes in ambient temperature, humidity, vibration, dust and corrosive elements? Are instruments and thermocouple circuits shielded from electromagnetic fields associated with high amperage furnace heating elements?
2 3
10
5 to 6 7 to 8 9 to 10
14. What controls does the heat treater use to indicate the processing and inspection status of products throughout the heat treating system. (QS-9000, Elements 4.8, 4.12 and 4.16) (Section III-Control Items) (HTX, 2.4, 3.4) Evaluate the method(s) used to show processing status: Note: Before heat treating vs. after heat treating Inspection status of parts, i.e., OK/rejected/hold. Positive identification procedure for accepted as well as rejected products. Fastener or control item processing may require special attention based on the processing requirement imposed by the "end user/customer."
Are effective controls in place to provide accurate part processing information throughout processing, storage, packaging and shipping? Describe in detail the type of shop traveler in use.
Are controls adequate to prevent movement of nonconforming rejected in-process products into the production system? Describe what measures (e.g., rejected material quarantine areas-see W-HTX, 2.4, 3.4 for requirements) are employed to prevent usage and/or shipment of defective and non conforming materials and products.
Material from different steel mill heats or metals which require different austenitizing, quenching, or tempering times and/or temperatures SHALL NOT BE MIXED OR PROCESSED TOGETHER.
3 to 5 6 to 7
9 to 10
15. Does the heat treater have complete records supporting Production Part Approval (PPAP) certification? (QS-9000 4.12, 4.16, PPAP), Section II) For PPAP samples submitted during the past two years, detailed, well organized supporting data is available? Is actual heat treat process related data available? Are preliminary statistical studies or process capability data available for all significant process parameters and/or product parameters? Are containment actions in place where required? Are Process FMEA and Dimensional/Process Control Plan available for each part or family of parts? When required, has product engineering approval of Product/Process Control Plans, samples and test equipment been documented? Are RSIR's performed according to plant procedures?
The essential point here is that complete supporting evidence must be available for the part of the process performed by the heat treater which impacts the PPAP. The STA or Heat Treat engineer must review several of the initial samples certified over the past two years. Note: Where the heat treater is a second tier heat treater to Ford's first tier heat treater it will be essential that the second tier heat treater perform PPAP, with submission of all necessary dimensional and physical data including FMEA and Product/ Process Control Plan, and required capability studies, to first tier heat supplier.
5 to 6
7 to 8
9 to 10
16. Does the heat treater react appropriately to customer concerns (internal or external indicators)? (QS9000, Elements 4.14 and 4.16) Are in-house and customer quality concerns effectively communicated to all members of the organization?
How are quality concerns communicated to production and support personnel? What methods are used to alert the entire production and support staff to quality concerns? (Typical methods are nonconforming parts displays and Pareto charts.) How is management alerted to quality concerns? Are nonconforming parts returned by customers analyzed? Is the root cause of failure (i.e., process and/ or system) determined, verified and corrective action taken?
Is the heat treat plant well facilitized to analyze nonconforming parts (e.g., stereo microscope, spectrometer, Magnaflux, eddy current, micro and macro hardness tester, etc.)? Does the heat treater have a certified individual(s), on staff, to perform metallurgical and non destructive analysis? Does the heat treater have a method to perform metallurgical and non destructive analysis if there is not a certified individual(s) on staff? Is a disciplined method of problem solving, e.g., the Eight Discipline format, utilized?
Are these indicators part of the heat treater's "Quality/Business Operating System" to evaluate continuous improvement? (e.g., Is the PPM (Parts Per Million) concept used to drive Continuous Improvement?)
7 to 8
10
Are appropriate records being maintained for the following atmosphere control related inspections and tests: Carbon potential checks of all carbon-bearing atmospheres by means of oxygen partial pressure, electrical resistance, complete gas analysis or CO2 content? (W-HTX, 2.1.4) Dew point may be used as the sole control only for atmosphere generators. Correlation between the control variable (CO2 content, O2 partial pressure, etc.) and the actual carbon potential of reactive carbon-bearing atmospheres (endothermic, carbon-enriched nitrogen, etc.) by means of shim stock, carbon gradient, etc.? Calibration of atmosphere controlling/monitoring equipment to assure accuracy of the readings in accordance with the manufacturers instructions? (W-HTX, 2.1.4)
Note:
Are instruments which monitor and record furnace push/cycles in use and appropriate records maintained? (W-HTX, 2.3) Are all temperature instruments (indicator, recording, controlling) labeled with identification of the calibrating company and most recent calibration date? Are records maintained of furnace temperature uniformity surveys (thermal profiles), where applicable, by use of a traveling thermocouple? (W-HTX, 2.1.1) For Induction Hardening review the heat treater's: Temperature control systems,(e.g., infra red units). Inductors case depth/runout capability. Energy Monitor Operation.
1 to 2
3 to 4 5 to 6
7 to 8 9 to 10
18. Are documented heat treat reject, reprocessing or scrap procedures available? Are reprocessed or sorted products subjected to an audit for conformance to all customer requirements? Assess the adequacy of the heat treater's reprocessing and sorting operation. (QS-9000, Element 4.13) Three basic areas should be reviewed: Are all reprocessing and scrap situations covered by documented procedures and standards?
These standards must clearly define what conditions require reprocess and what conditions require scrapping the part. Note: Product which does not meet print specification after initial heat treatment and which could be corrected with reprocessing, may require prior engineering approval. An effective lot control system must be in place to ensure their movement and processing.
Since reprocessing can cause new nonconformance (e.g., physical and mechanical properties of the parts), a complete check of all special characteristics is required. Also, visual and functional checks (ES tests) must be made. Are there documented efforts to eliminate the need for reprocessing?
Cause of reprocessing should be analyzed using basic quality and problem solving tools (including statistical methods and verification of upstream system controls) refer to sections IV and V.
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6 7 8
9 10
19. Are heat treat processing, handling, storage and packaging adequate to preserve product quality? (QS9000, Element 4.15)(Section III)(W-HTX, 1.7, 2.4, 3.4) During the review of the heat treater's process, attention should be paid to product handling.* The product, where appropriate, should be protected against damage and contamination.* Storage areas for incoming, in-process and finished products should be reviewed to determine if any conditions exist which could affect product quality. Packaging should be reviewed for adequacy. Seek answers to the following concerns: bar coding requirements design of the containers and conveyor system which will reduce part entrapment. cleanliness of containers. loading of containers: condition of the containers/baskets and conveyors. damaging the product, during heat treatment and packaging. potential for mixing of non-heat treated vs. heat treated product. general cleanliness of the shop. status identification of containers throughout the processing cycle. foreign material in containers Note: It is essential that every container being used for transfer and/or transportation of parts should have status identified. IF containers with parts and "NO STATUS IDENTIFICATION TAG" are found during the audit the maximum score allocation should be "4."
3 to 4 5 to 6 7 to 8
9 to 10
20. Are plant cleanliness, housekeeping, environmental, and working conditions conducive to quality improvement? (QS-9000, Element 4.9),(Section II) This question seeks information on the suitability of the heat treater's plant for the commodity and processes involved. Is it reasonable to expect high quality and continuous improvement from these facilities? Are there working conditions that could be detrimental to quality improvement?
Review heat treater's housekeeping procedure with emphasis on potential major risk areas, such as, but not limited to: Miscellaneous loose parts and unidentified containers/baskets around processing equipment. Cleaning sequence of Austenitizing/Tempering furnaces for loose parts which may have fallen off the conveying system. Dredging sequence for the quench tanks to remove scale and loose parts. Flash and fire point checks of quench oil to safeguard against contamination which could create fire hazards. Oil spill around quench tanks. Condition of area around shot blast and storage of incoming and quarantined parts which could affect product quality. Overall plant lighting (especially at the mechanical and the visual inspection areas), floor markings, identified utility lines and work area identification signs. Inadequate storage facilities which could affect product quality. Could product quality be affected by plant environment? Does the facility meets the OSHA, state and/or appropriate country's standards? Verify.
Ar3 Ar4 Ms Mf
NOTE All these changes except the formation of martensite occur at lower temperatures during cooling than during heating, and depend on the rate of change of temperature. X bar R Mean (Average) Value and Range
A. General Information
Division
H.T. Supplier Name____________________________ Supplier Code________________________________ Plant________________________________________ Address_____________________________________ City_________________________________________ State/Country and Postal Code__________________ Phone No. (area code)_________________________ Quality Manager______________________________ Ford Engineer________________________________ Supplier in Conformance with Ford Heat Treat System Survey yes_____ No____ Corrective action required yes_____ No____ Survey No Date (If part is outsoursed for heat treat) Heat Treat Service Provided To: ____________________________________________ Address_____________________________________ City_________________________________________ State/Country and Post Code___________________ Phone No. (area Code)_________________________ Quality Manager______________________________
HEAT TREAT SYSTEM SURVEY REPORT C. FORD PARTS, PROCESS AND SPECIFICATION LIST:
Part Name 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Part Number Material Process Hardness (Surf/Core) Case Depth (Effectiv/Total)
Rating
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TOTAL PLANNING FOR QUALITY (total points available =30) B. STATISTICAL METHODS
4. Is statistical Process Control (SPC) utilized for special product characteristics and process parameters? How are the special characteristics chosen? Describe the SPC methods used. Are they appropriate to the factors being controlled? Evaluate the heat treaters reaction to out-of-control conditions. Is the reaction as specified in the Control Plan? What is the role of the operator? Evaluate the heat treaters application of SPC, based on the evidence of the control charts, process logs and other appropriate documentation. 5. Are process verification/capability studies conducted on new product characteristics and heat treat process parameters? 6. Are statistical control charts being used effectively to monitor the process? Do control charts indicate that the statistical control has been achieved and that process capability has been demonstrated? In all cases where process capability has not been demonstrated, is there a plan to improve the process? Is appropriate interim action being taken to prevent shipment of non-conforming parts? 7. Does the heat treater have a definite program to bring about continual improvement in quality and productivity? Describe the program. Indicate the tools being used for continual improvement.
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Rating
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Rating
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TOTAL GENERAL (Total points available = 80) ________ D. IN-PROCESS AND OUTGOING
17. Are process monitoring and inspection/tests performed according to the instruction sheet? Are there adequate records of inspection and tests? 18. Are documented heat treat reject, reprocessing or scrap procedures available? Are reprocessed parts audited for conformance to all customers requirements? Assess the adequacy of the procedures. 19. Are heat treat processing, handling, storage and packaging adequate to preserve product quality? Assess the heat treater's furnace loading system, in-process handling and shipping process for any cause of concerns. 20. Are plant cleanliness, housekeeping, environmental, and working conditions conducive to Quality improvements? Are there working conditions that could be detrimental to quality improvement? Could product quality be affected by plant environment? _______
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Conformance to QS-9000, Heat Treat System Survey Scoring Guidelines and W-HTX requires at least a 7 rating on each individual element and at least a 160 overall System Survey Rating. Suppliers should provide improvement action plans for all areas with a rating below 7 within 60 days.