CQI-15焊接系统评估.docx

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1、CQH 5AIAG,AutomotiveIndustryActionGroup美国汽车工业行动集团SpecialProcess:WeldingSystemAssessmentCQM5SpecialProcess:WeldingSystemASiieUSment特殊过程:焊接系统评估Version版本号1ISSUed发行日期3/10ABOUTAIAGAIAGPurposeStatement目的声明Foundedin1982,AIAGisagloballyrecognizedorganizationwhereOEMsandsuppliersunitetoaddressandresolveissue

2、saffectingtheworldwideautomotivesupplychain.AIAGsgoalsaretoreducecostandcomplexitythroughcollaboration;improveproductquality,health,safetyandtheenvironmentjandoptimizespeedtomarketthroughoutthesupplychain.美国汽车工业行动集团(AIAG)成立于1982年，是由OEM厂商和供应商联手组建的一家全球公认的著名机构，旨在体现并解决影响全球汽车供应链的诸多问题。AIAG的目标是通过相互协作，降低产品的

3、成本及复杂性；提高产品质量，改善员工健康、安全与环境；并优化产品在整个供应链范围内的上市速度。AIAGOrganizationAIAG组织构成AIAGismadeupofaboardofdirectors,anexecutivedirector,executivesonloanfrommembercompanies,associatedirectors,afull-timestaff,andvolunteersservingonprojectteams.Directors,departmentmanagers,andprogrammanagersplan,directandcoordinate

4、theassociationsactivitiesunderthedirectionoftheexecutivedirector.AIAG由董事会、一名执行董事、多名来自成员公司的贷款事务高级管理人员、多名副董事、一位全职职员以及为项目团队服务的志愿者组成。董事、部门经理与项目经理在执行董事的领导下，负责计划、指导和协调组织活动。AIAGProjectsAIAG项目Volunteercommitteesfocusonbusinessprocessesorsupportingtechnologiesandmethodologies.Theyconductresearchanddevelop,pu

5、blish,andprovidetrainingonstandards,conventions,standardbusinesspractices,whitepapers,andguidelinesintheareasofautomaticIdentificationjCADZCAM,EDIZeIectroniccommerce,continuousqualityimprovement,healthfocus,materialsandprojectmanagement,occupationalhealth&safety,returnablecontainersandpackagingsyste

6、ms,transportation/customsandtruck&heavyequipment.志愿者委员会重点关注业务流程或是支持技术与方法。他们会开展研究，撰写并出版相关标准、协定、标准业务做法、白皮书以及指导原则，并就此提供培训；涉及的领域包括自动识别、CAD/CAM.EDI/电子商务、持续质量改进、关注健康、材料和项目管理、职业保健与安全、可回收容器与包装系统、运输/通关以及卡车与重型设备。AIAGAulomolivs Industry Acton.GroupCQM5SpecialProcess:WeldingSystemAssessment森殊过程:焊接系统评估VerSion版本号

7、USSUed发行日期3/10AIAGPUBLICATIONSAIAG出版物AnAIAGpublicationreflectsaconsensusofthosesubstantiallyconcernedwithitsscopeandprovisions.AnAIAGpublicationisintendedasaquidetoaidthemanfacturer,theconsumerandthegeneralpublic.TheexistenceofanAIAGpublicationdoesnotinanyrespectprecludeanyonefrommanufacturing,marke

8、ting,purchsing,orusingproducts,processes,orproceduresnotConfortningothePUbliCanon.AlAG出版物反映出了在重大关注事项的范围及其规定上的一致意见,AlAG出版物旨在作为一个指南,以协助制造斶、消费者和普通大众.AIAG出版物的存在于任何方面都不能避免有人会使用不符合本出版物的产品、流程或程序,来制造、营销、采购或使用产品。CAUTIONARYNOTICE告诚性通知AlAGpublicationsaresubjecttoperiodicreviewandusersarecautionedtoobtainthelat

9、esteditionsAlAG出版物会进行定期审核,并告诚用户注意获取及新版本。MAINTENANCEPROCEDURE维护程序RecognizingthatthisAIAGpublicationmaynotcoverallcircumstances,AIAGhasestablishedamaintenanceprocedure.PleaserefertotheMaintenanceRequestFormatthebackofthisdocumenttosubmitarequest.考虑到本AlAG出版物可能无法涵盖所有情况,AlAG已为此建立了一个维护程序。请参阅本文件后面的“维护申语走“，

10、以提交申请。出版单位:Fbblishedby:AutomotiveIndustryActionGroup美国汽车工业行动集团26200LahserRoadfSuite200SouthfieIdjMichigan48033PhOne:电话:(248)358-3570Fax:传真:(248)358-3253APPROVALSTATVS批准状态TheAIAGQualitySteeringCommitteeanddesignatedstakeholdersapprovedthisdocumentforpublicationonAugux1,2007AIAG质量指导委员会和指定的风险承担人于2007年8

11、月1口批准本文件出版发行。March2010.AIAGCOPYRIGHTANDTRADEMARKNoTICE:AIAG版权与商标的注意事项:ThecontentsOfallpublishedmaterialsarecopyrightedbytheAutomotiveIndustryActionGroupunlessotherwiseindicated.CopyrightisnotclaimedastoanypartofanoriginalworkpreparedbyaU.S.orstategovernmentofficeroremployeeaspartofthepersonsoficiald

12、uties.AllrightsarepreservedbyAIAG,andcontentmaynotbealteredordisseminated,published,ortransferredinpartofsuchcontent.Theinformationisnottobesoldinpartorwholetoanyonewithinyourorganizationortoanothercompany.CopyriahtinfringementisaviolationOffederallawsubiecttocriminalandcivilpenalties.AIAGandtheAuto

13、motiveIndustryActionGroupareregisteredservicemarksOftheAutomotiveIndustryActionGroup.除非另有说明,否则所有出版材料内容的版权均归美国汽车工业行动集团所有。对由美国或州政府富员或是雇员作为其个人公务职责的部分而编写的任何原作部分,不会提出版权诉求,AlAG保留所有权利,不得对内容进行更改,或是传播、出版或转载其中的部分内容.不得将信息部分或全部转卖给组织内的任何人或另一家公司。长犯版权是违反联邦法律的,会受到刑事与民事处罚。AlAG和AutomotiveIndustryActionGnmP是美国汽车工业行动集团

14、的注册极务商标。2007AutomotiveIndustryActionGroupC2007年美国汽车工业行动集团版权所彳iAIAGDAUometie IndUaiV ACtion GrOUdSpecialProcess:WeldingSystemASSeSSmem特殊过程:焊接系统评估VerSion版本号1ISSUed发行日期3/10CQM5SpecialProcess:WeldingSystemAssessment.碍殊过程:焊接系统评店VerSion版本号IlSSUed发行日期3/10FOREWORD前言AutomotiveIndustryActionGroup(AIAG)committ

15、eesaremadeupofvolunteersfrommembercompaniesintheautomotiveindustry.TheworkofpreparingprocessauditsisdonebyAIAGtechnicalcommittees.汽车工业行动组(AIAG)委员会由来自汽车行业内各成员公司的志愿者组成。流程审核的准备工作是由AlAG技术委员会完成的。ThemaintaskoftechnicalcommitteesistoprepareAutomotiveStandardsandSystemRequirements.Draftdocumentsadoptedbythe

16、technicalcommitteesarecirculatedtotheSteeringCommitteeforreviewandconsensusapproval.PublicationofthedocumentsrequiresapprovalbytheQualitySteeringCommittee.技术委员会的主要任务是准备汽车标准与系统要求。技术委员会所采用的草案文件要送交指导委员会以供审核并获得一致批准。文件的出版发行需要得到质量指导委员会的批准。TheQualitySteeringCommitteewouldliketoacknowledgeandthankthefollowi

17、ngindividualsandtheircompanieswhohaveContribuiedtimeandeffortto(hedevelopmentofthisdocument质量指导委员会想藉此机会，表彰以下为文件的制订付出了大量时间及精力的个人及所属公司，并向他们表示感谢。ACKNOWLEDGEMENTS致谢CoreMemberS:核心成员：JosephBeckhamChryslerGroupLLCGilbertChrostowskiTRWAutomotiveVirenderChoudhriDelphiCorporationThomasLopiccoIoGeneralMotorsCo

18、mpanyNealMcMichaelFordMotorCompanyCarlOcchialiniTheLincolnElectricCompanyVeronicaSebaldToyotaMotorEngineering&Manufacturing,NorthAmericaRyanTurnwaldHondaofAmericaManufacturingJnc.DaveWilligNexteerAutomotiveAIAGDAINMndkeIndunlirv AcUonGroiieCQ1-15SpecialProcess:WeldingSyStemASSeSSment特殊过程：焊接系统评估VerSi

19、on版本号IISSUed发行日期3/10TABLEOFCoNTENTS目录ABOUTAIAG关于AlAG1FOREWORD前言3ACKNOWLEDGEMENTS致谢3TABLEOFCONTENTS目录4INTRODUCTION简介5GENERAL综述5PROCESSAPPROACH流程步骤5WELDINGSYSTEMASSESSMENTGOALS焊接系统评估目标5ASSESSMENTPROCESS评估过程5ASSESSORQUALiFICATIoNS.审核员资格6OTHERREQUlREMENTS其他要求61SCOPE范围712APPLICATl展用71.3REFERENCE参考文献82 TH

20、EWELDINGSYSTEMASSESSMENTPROCEDURE焊接系统评估过程93 SPECIALPROCESS:WELDlNGASSESSMENT特殊过程：焊接评估10APPENDIXA-PROCESSTABLES附录A-流程表3149GLOSSARY术语表CQM5翻凰ic年黑螂成部限镖混S*发行日INTRODUCTION简介General综述TheworkofpreparingCQI-15:SpecialProcessiWeldingSystemAssessment(WSA)wascarriedoutthroughtheAIAGWeldingWorkGroup.Thesewelding

21、requirementsarecomplementarytocustomerandproductstandards.CQI-I5:特殊过程：焊接系统评估(WSA)的湘备工作由AIAG焊接工作组完成，这些焊接标准作为客户标准和产品标准的补充要求。TheWSAcanbeusedtoassessanorganization1sabilitytomeettherequirementsinthisassessment,aswellascustomer,regulatory,andtheorganizationsownrequirements.TheWSAcanalsobeusedbetweenanorg

22、anizationanditsSUPPIierS.WSA可以用来评估家企业达到评估标准的能力，也可以是达到客户的要求、行业规定和企业自定的标准。WSA也可以在企业与其供必须商之间使用IntheWSA,thewordshallindicatesarequirementforpurposesoftheselfassessment.FailuretomeettherequirementsresultsinanassessmentthatiseitherNotSatisfactoryorNeedsImmediateAction.Theword,should,indicatesarecommendati

23、on.Wherethetermsuchasisused,anysuggestionsgivenareforguidanceonly.在WSA中，“必须”一词表明这是一项自我评估的要求。如果未能达到标准，则评估结果显示为“不理想”或“需要立即改进”。“应该”一词表明某项建议。如果在文中出现“比如”一词，则表明下列建议仅供参考。ProcessAPPrOaeh流程步骤TheWSASUPpOrtStheautomotiveprocessapproachasdescribedinISO/TS16949.WSA支持ISozTS16949:2002中描述的汽车流程步骤。WeldingSystemAssess

24、mentGoaIS焊接系统评估目标ThegoaloftheWSAisthedevelopmentofaweldingmanagementsystemthatprovidesforcontinualimprovement,emphasizingdefectpreventionandthereductionofvariationandwasteinthesupplychain.WSA的目标是对焊接管理系统的发展，以提供持续的完善，强调对供必须链中差错的预防，减少波动和浪费TheWSA,coupledwithaninternationallyrecognizedqualitymanagementsy

25、stemandapplicablecustomer-specificrequirements,definesthefundamentalrequirementsforweldingmanagementsystems.WSA配合国际公认的质量管理系统和使用的客户特定要求，详细说明了对焊接管理系统的基本要求。TheWSAisintendedtoprovideacommonapproachtoaweldingmanagementsystemforautomotiveproductionandservicepartOrganiZaIiOnS.WSA旨在为汽车生产件和售后服务柞公司提供一个共同的焊接管理

26、系统方法。AssessmentPrOCeSS评估过程AIAGDUomoHe IndUery ffnGiSpecialProcess:WeldingSystemAssessmentVerSiOn版本号IISSUed发行日期3/10Ongoingassessmentsshallbeconductedannually,unlessotherwisespecifiedbythecustomer,toreexaminethecontinuingcompliancewiththeWSA.Eachassessmentshallincludeareviewoftheorganizationssystemsus

27、ingtheWSA.SuccessiveJobAudits（Section6.0ofthisdocument）shallsamplepartsfromdifferentautomotivecomponentmanufacturersthatrequirecompliancetotheWSAdocument.除非客户有特别要求（对WSA要求的符合程度进行再次检查），一般情况下评估过程必须每年进行一次。每次评估必须包括使用WSA对企业系统进行检查。连续工作审核（见本文第六部分）必须采集汽配制造商的零部件样本检测其是否符合WSA的标准。Theassessmentshallusetheprocessa

28、pproachtoauditingasidentifiedbytherequirementsofISO/TS16949.评估必须使用ISO/TS16949规定的流程步骤来审核/评估。CQM 5AIAGAUtemoliVeIndUStryACflon/GouoAssessorQualifications核员资格Assessor(s)shallhavethefollowingspecificexperiencetoconducttheWELDINGSYSTEMASSESSMENT:审核员必须具有下列具体经验，才能来进行焊接系统评估。1 .Beanexperiencedqualitymanageme

29、ntsystem(QMS)intemalauditor(forexample,latesteditionofTSO/TS16949,IS09001)资深的质量管理系统(QMS)内部审核员(比如：TSO/TS16949、ISO9001的最新版)。2 .Assessorshallpossessweldingknowledge.Evidenceshallincludeaminimumof5yearsexperienceinweldingoracombinationofformaleducationinweldingandweldingexperiencetotalingaminimumof5year

30、s.审核员必须具有焊接专业知识。包括至少5年的焊接和表面精加工的经验，或接受过正规焊接教育和焊接工作经验的总年限不少于5年。3 .Assessorshallpossessknowledgeofandbefamiliarwiththeapplicationofautomotivequalitycoretoolsincludingstatisticalprocesscontrol,measurementsystemsanalysis,partapproval,failuremodeandeffectsanalysis,andadvancedqualityPlanning.审核员必须具有包括统计过痉

31、控制、测量系统分析、零件认可、失效模式和后果分析，以及先期质量策划等汽车质量核心工具的相关知识，并能熟练运用。NoteiIfmorethanoneassessorisrequiredtomeettheabovequalifications,theleadassessorshallbethepersonmeetingtherequirementsinitem#1.如果有多名审核员符合以上要求，则主审员应由最符合以上各条（或第一条）要求的人员担任。OtherRequirements其他要求Theorganizationshallkeeprecordsasevidenceofcomplianceto

32、therequirementsidentifiedintheWSA,aswellasallappropriateactionplanstoaddressanyunsatisfactoryratings.Theserecordsshallbereadilyavailableforreviewbyanycustomerrequiringcompliancetotherequirementswithinthisdocument.企业必须保留相关记录，证明己达到WSA标准，同时记录所有为改善不理想的评估项目而采取的适当改进计划。这些记录必须为客户准备，以便客户对记录中的要求的符合情况进行复检。AlAG

33、、AWOmOtke IndUniry Aetion GroU&SpecialProcess:WeldingSystemASSeSSmeE特殊过程:焊接系统评估VerSiOn版本号1Issued发行日期3/101SCOPE范围1.1 General综述Thisdocumentspecifiesprocessrequirementsforanorganizationoritssuppliersperformingapplicablewelding,whoneedt。:本文详细说明了企业或其供应商在进行焊接时的流程要求，需要： demonstrateabilitytoconsistentlyprov

34、ideproductthatmeetscustomerandapplicableregulatoryrequirements,and证明具有持续提供符合客户和使用规范标准的产品的能力。 enhancecustomersatisfactionthroughtheeffectiveapplicationofthesystem,includingprocessesforcontinualimprovementoftheSyStem.通过有效应用系统，包括持续改进系统流程，提高客户满意度。TheWeldingSystemAssessmentisapplicabletositeswherecustome

35、r-specifiedpartsforproductionand/orserviceareprocessedthroughouttheautomotivesupplychain.焊接系统评估适用于汽车供链中各个加工客户指定的用于生产和/或售后服务的零部件的厂点。1.2 APPIiCatiOn应用AllrequirementsoftheWSAaregenericandareintendedtobeapplicabletoallorganizationsperformingtheweldingoperationsaddressedinthisdocument,regardlessoftype,si

36、ze,andProdUCt.WSA所有的标准都是普遍使用的，适用于所有企业进行本文描述的焊接操作，不论型号、大小和产品的区别。NoteiFourProcessTableshavebeendevelopedandtheappropriatetable(s)istobereferencedduringtheassessmen.TheProcessTablesarespecifictoweldingprocessesasnotedbelow:注：编写了四张流程表，相应的表格可在评估过程中做参考用。流程表的详细焊接程序如下所示：ProCeSSTabIeA-ArCWeldinB流程表A电弧焊ArcStu

37、cVFastenerWelding电弧/紧固件焊接Flux-CoredArcWeIding包芯焊条电弧焊GasMetalArcWeIding气体保护金属极电弧焊SubmergedArcWelding埋弧焊ShieldedMetalArcWekiing自动保护金属极电弧焊PlasmaArcWeIding等离子弧焊GasTungstenArcWCkling气体保护铝极电弧焊GasMetalArcBrazeWeIding气体金属电弧钎焊ProCeSSTableB-ReSiStanCeWelding流程表B-电阻焊ResistanceSpotWelding接触点焊ProjectionWelding凸焊

38、ResistanceSeamWekIing电阻缝焊High-FrequencySeamWeIding频缝焊AIAG、AUIernOne IndUStry ACHan.GiouCQM5SpecialProcess:WeldingSystemAssessment卷冰过程:獐搂素经评剧ersion版本号IISSUed妥行日期3/10InductionSeamWelding感应缝焊MashSeamWeIding滚压电阻缝焊FlashWelding闪光对焊AlAG、AUtOinet IndlIef ACtOn Groug.SpecialProcess:WeldingSystemASSeSSmem特殊过程

39、:焊接系统评估VerSion版本号IlSSUed发行日期3/10PrOCeSSTableC-LaSerWeIding流程表C一激光焊接NdYAG教激光CO2二氧化碳DIODE二极管WireFed联邦储备总线ProCeSSTabIeD-SOlidStateWeIdiIIe流程表D固态焊接InertiaFrictionWelding储能摩擦焊接DirectDriveFrictionWelding直接驱动摩擦焊接FrictionStirWeIding搅拌摩擦焊接FlashButtWelding闪光对接焊ResistanceButtWeklingEa阻对焊UltrasonicWelding超声波焊接T

40、heseProcessTablescontainrequirementsfor:这些过程表包含下列要求：1. ManagementResponsibility&QualityPlanning管理责任和质量策划2. FloorandMaterialHandlingResponsibilityZE与物料处理责任3. EquipmcntzFacilitiesZControls设备/设施/控制4. ToolingZFixturing模具/夹具5. ProcessControlsandConfirmation过程控制与确认6. EssentialVariableS基本变量TheProcessTables

41、specifythetolerancesofprocessparametersandthefrequenciesforcheckingprocesscontrolparametersandparts.TheRequirementsandGuidanceintheWSAformwillnotifytheassessorwhentorefertotheProcessTabIeS.流程表规定了参数的公差和检查控制参数与零件而频率。WSA表格中的要求与指南将提示审核员何时应参考流程表。13ReferenCe参考文献Thefollowingstandardsareusedasreferencemater

42、ial.Therearcotherreferencematerialsthatcontainmoreinformation,however,thelistisnotmeanttobeinclusive.Theapplicabilityislimitedtothesubjectmatterreferenced.以下标准作为本文件的参考资料，然而，本文件还引用了其他包含更多信息的参考材料，因此列表并不包含所有参考文献在内，其适用范围仅限于所引用的主题方面。StandardNUlnber标准编号TitIe标准名称Standard*sOrganiZation标准发布机构ANSIZ49.1Safetyi

43、nWeldingandCUtting焊接与切割安全ANSI-www.ansi,orgWS3.0StandardWeldingTermsandDefinitionS标准焊接术语和定义WWw.aws.orgWSC7.2RecommendedPracticesforLaserBeamandWeIding激光束焊接推荐规程www.aws.orgAlAG、AUkemOIHVeIndUStrYAefonGoUO2 THEWELDINGSYSTEMASSESSMENTPROCEDURE焊接系统评估过程1. ObtaincurrentcopyofCQl-15SpecialProcess:WeldingSyst

44、emAssessment,fromAIAG.MAIAG获取最新的CQI-15特殊过程：焊接系统评估。2. IdentifyallweldingprocessestowhichCQI-15SpecialProcess:WeldingSystemAssessment,applies(seeCQI-15,1.2).RecordtheseprocessesontheWSA.确认CQI-15特殊过程：焊接系统评估所使用的焊接流程。将这些流程记录在WSA第一页上。3. CompletetheWSA,determiningthelevelofcompliance.Aminimumofonejobaudit(

45、Section6)shallbeperformedduringeachassessment.完成WSA,确定符合度。每次评估必须至少由一名工作审核员(第六部分)进行。4. AddresseachNotSatisfactorynItemanddeterminecorrectiveaction,includingrootcauseanalysisandimplementationofthecorrespondingcorrectiveaction(s).Thecorrectiveaction(s)shallbecompletedwithin90days.Recordsofthecorrective

46、action,includingverification,shallbemaintained.分析每一个不理想的环节，并确定正确的行动方案，包括分析问题根源，并执行相应的纠正措施。纠正措施必须在90天内完成。有关记录，包括验证记录必须收录在案。5. uNeedsImmediateAction,requiresimmediatecontainmentofsuspectproduct.AddresseachttNeedsImmediateAction,itemanddeterminecorrectiveaction(s),includingrootcauseanalysisandimplement

47、ationofthecorrespondingcorrectiveaction(s).Thecorrectiveaction(s)shallbecompletedwithin90days.Recordsofthecorrectiveaction,includingverification,shallbemaintained.“需要立即改进”表示要求立刻保留问题产品。解决每一个“需要立即改进”的环节，并确定正确的行动方案，包括分析问题根源，并执行相应的纠正措施。纠正措施必须在90天内完成。有关记录，包括验证记录必须收录在案。6. Assessmentsshallbeconductedannual

48、lyunlessotherwisespecifiedbythecustomer.户另有要求，评估必须每年进行一次。AIAGDAutemoNc InducHy Acton GmuCQ1-153 SPECIALPROCESS:WELDINGASSESSMENT特殊过程：焊接评估CoverSheet封面表单15Section1-5第一至第R部分18Section 1: ManagementResponsibility&QualityPlanning第一部分：管理责任和质量策划18Section 2: FloorandMaterialHandlingResponsibility第二部分：工厂与物料处理责任24Section 3: EqUiPmenl第三部分：设备26Section 4: Too