Special Process: Plating System Assessment, 2nd Edition
CQI-11Special Process: Plating System AssessmentVersion 2 Issued 2/2012Special Process: Plating System Assessment, 2nd EditionFacility Name: Master Finish CompanyAddress:2020 Nelson SEGrand Rapids, MI 49510Phone Number: (616) 245-1228Fax Number: (616) 245-0039Number of Plating Employees at this Facility: 90Type(s) of Plating Processing at this Facility:Process Table A:ZincNoZinc Alloy PlatingNoCaptive Plater (Y/N): NCommercial Plater (Y/N): YProcess Table B:Mechanical PlatingDate of Assessment: May 23-June10, 2016Process Table C:Surface Conditioning of Metals for Decorative Plating orElectropolishingPreplate Vibratory Finishing andElectropolishingSurface Conditioning of Plastics for Decorative PlatingNoDate of Re-assessment (if necessary):N/ANoProcess Table E:Decorative Plating for Metal and PlasticMetal Yes / Plastic NoProcess Table F:Electropolishing and/or Chrome Flash on Stainless SteelProcess Table G:Hard Chrome PlatingNoProcess Table H:Electroless NickelNoProcess Table I:Hydrogen Embrittlement Relief Bake ProcessProcess Table J :Process Control and Testing EquipmentYesYesYesCurrent Quality Certification(s): ISO9001:2008Personnel Contacted:Name:John MulderAaron MulderGordan LozicMatthew LomasneySteve PhillipsJohn HaleyDeborah KokerTitle:COOVP EngineeringQuality ManagerChemical EngineerOperations ManagerMaintenance ManagerQC Lab TechAuditors/Assessors:Name:Rachel NederhoedCompany:Master Finish ne:616-245-1228Number of "Not Satisfactory" Findings:NoneNumber of "Needs Immediate Action" Findings:NoneNumber of "Fail" Findings in the Job Audit(s):NoneNumber of Process Table items identified as failed in Comments/Observation column:None 2012 AIAG (Automotive Industry Action :rnederhoed@masterfinish.com
CQI-11Special Process: Plating System AssessmentVersion 2 Issued 2/2012Special Process: Plating Process Assessment (General Facility nts and GuidanceObjective EvidenceN/ASatisfactorySection 1 - Management Responsibility and Quality PlanningIs there a dedicated andqualified plating person onsite?To ensure readily available expertise, there shall bea dedicated and qualified plating person on the site.This individual shall be a full-time employee and theposition shall be reflected in the organization chart. Ajob description shall exist identifying thequalifications for the position including chemical andplating knowledge. The qualifications shall include aminimum of 5 years experience in plating andsurface finishing or a combination of formalchemistry/chemical engineering education andplating experience totaling a minimum of 5 years.Does the plater performadvanced quality planning?The plater shall incorporate a documented advancequality planning procedure. A feasibility study shallbe performed and internally approved for each part.Similar parts can be grouped into part families forthis effort as defined by the plater. After the partapproval process is approved by the customer, noprocess changes are allowed unless approved by thecustomer. The plater shall contact the customerwhen clarification of process changes is required.This clarification of process changes shall bedocumented.1.3Are plater FMEA's up to dateand reflecting currentprocessing?The plater shall incorporate the use of a documentedFailure Mode and Effects Analysis (FMEA)procedure and ensure the FMEAs are updated toreflect current part quality status.The FMEA shall be written for each part or partfamily or they may be process-specific and written foreach process. In any case, they shall address allprocess steps from part receipt to part shipment andall key plating process parameters as defined by theplater. A cross-functional team shall be used in thedevelopment of the FMEA. All characteristics, asdefined by the plater and its customers, shall beidentified, defined, and addressed in the FMEA.1.4The plater shall incorporate the use of a documentedControl Plan procedure and ensure the Control Plansare updated to reflect current controls. The ControlPlans shall be written for each part or part family orthey may be process-specific and written for eachprocess. In any case, they shall address all processsteps from part receipt to part shipment and identifyall equipment used and all key plating processparameters as defined by the plater. A crossAre finish process Controlfunctional team, including a production operator,Plans up to date andshall be used in the development of Control Plans,reflecting current processing?which shall be consistent with all associateddocumentation such as work instructions, shoptravelers, and FMEAs. All special characteristics, asdefined by the plater and its customers, shall beidentified, defined, and addressed in the ControlPlans. Sample sizes and Frequencies for evaluationof process and product characteristics shall also beaddressed consistent with the minimum requirementslisted in the Process Tables.1.11.2 2012 AIAG (Automotive Industry Action Group)Organizational Chart,Plating Mgr. Job Description,Plating Process Engineer JobDescription,Chemical Engineer Job DescriptionAPQP ProcessXXPart Specific FMEAsXPart Specific Control PlansXNotSatisfactoryNeeds ImmediateAction
CQI-11Special Process: Plating System AssessmentVersion 2 Issued 2/2012Special Process: Plating Process Assessment (General Facility nts and GuidanceObjective EvidenceN/ASatisfactorySection 1 - Management Responsibility and Quality PlanningAre all plating related andreferenced specificationscurrent and available? Forexample: SAE, AIAG, ASTM,General Motors, Ford, andChrysler.To ensure all customer requirements are bothunderstood and satisfied, the plater shall have allrelated plating and customer referenced standardsand specifications available for use and a method toensure that they are current. Such standards andspecifications include, but are not limited to, thoserelevant documents published by SAE, AIAG, ASTM,General Motors, Ford, and Chrysler. The plater shallhave a process to ensure the timely review,distribution, and implementation of all customer andindustry engineering standards and specificationsand changes based on customer-required schedule.This process shall be executed as soon as possibleand shall not exceed two weeks. The plater shalldocument this process of review and implementation,and it shall address how customer and industrydocuments are obtained, how they are maintainedwithin the plating organization, how the currentstatus is established, and how the relevantinformation is cascaded to the shop floor within thetwo-week period. The plater shall identify who isresponsible for performing these tasks.1.6Is there a written processspecification for all activeprocesses?The plater shall have written process specificationsfor all active processes and identify all steps of theprocess including relevant operating parameters.Examples of operating parameters include processtemperatures, cycle times, load rates, rectifiersettings, etc. Such parameters shall not only bedefined, they shall have operating tolerances asdefined by the plater in order to maintain processcontrol. All active processes should have a writtenprocess specification. These process specificationsmay take the form of work instructions, job card,computer-based recipes, or other similar documents.1.7To demonstrate each process is capable of yieldingacceptable product the plater shall perform productcapability studies for the initial validation of eachprocess, after relocation of any process equipment,and after a major rebuild of any equipment. Theplater shall define what constitutes a major rebuild.Initial product capability studies shall be conductedfor all plating processes per line as defined in scopeHas a valid product capability of work and in accordance with customerstudy been performed initially requirements. Capability study techniques shall beand after process change?appropriate for the plating product characteristics,e.g. plate thickness, corrosion resistance, etc. Anyspecific customer requirements shall be met. In theabsence of customer requirements, the plater shallestablish acceptable ranges for measures ofcapability. An action plan shall exist to address thesteps to be followed in case capability indices falloutside customer requirements or establishedranges.1.51.81.91.10Does the plater collect andanalyze data over time, andreact to this data?Are records retained andavailable?Does management reviewand verify bake oven logs forparts requiring hydrogenembrittlement relief every 24hours?The analysis of products and processes over timecan yield vital information for defect preventionefforts. The plater shall have a system to collect,analyze, and react to product or process data overtime. Methods of analysis shall include ongoingtrend or historical data analysis of special product orprocess parameters. The plater shall determinewhich parameters to include in such analysis.All process control and testing records must beretained for a minimum of one calendar year after theyear in which they were created.Management shall review the oven monitoringsystems/logs at intervals not to exceed 24 hours orprior to parts being released for shipment. Theplater shall have reaction plans for nonconformances to process requirements. This is tocontain, at minimum, requirements for quarantiningmaterial and notifying customer. 2012 AIAG (Automotive Industry Action Group)Current Plating Specification List w/electronic copies of specifications andindustry standards,Annual Book of ASTM Standards***Computer-based Recipes,Routing Tags,Work Instructions,Analysis Sheets,pH and Temp SheetsXXProduct Capability Study RecordsXKPI ReportTrueChemMasterTracker RecordsXProcess Analysis RecordsQC Lab Test Records***Electronic Inspection RecordsXHydrogen Embrittlement Log,Oven Chart,MasterTracker Electronic RecordsXNotSatisfactoryNeeds ImmediateAction
CQI-11Special Process: Plating System AssessmentVersion 2 Issued 2/2012Special Process: Plating Process Assessment (General Facility nts and GuidanceObjective EvidenceSection- Managementand QualityThe plater shallconduct1internalassessments onResponsibilityanannual basis, at a minimum, using the AIAG PSA.CQI-11 Audit RecordsConcerns shall be addressed in a timely manner.N/ASatisfactoryPlanning1.11Are internal assessmentsbeing completed on anannual basis, at a minimum,incorporating AIAG PSA?1.12The quality management system shall include adocumented process for reprocessing that shallinclude authorization from a designated individual.The reprocessing procedure shall describe productcharacteristics for which reprocessing is allowed asIs there a system in place to well as those characteristics for which reprocessingauthorize reprocessing and is is not permissible. All reprocessing activity shallit documented?require a new processing control sheet issued byqualified technical personnel denoting the necessaryplating modifications. Records shall clearly indicatewhen and how any material has been reprocessed.The Quality Manager or a designee shall authorizethe release of reprocessed product.Electronic QA Hold / Reworkauthorization procedureProcessing Control SheetX1.13The quality management system shall include aDoes the Quality Departmentprocess for documenting, reviewing, and addressingreview, address, andcustomer concerns and any other concerns internaldocument customer andto the organization. A disciplined problem solvinginternal concerns?approach shall be used.Customer Complaint Log,Corrective Action Log,ISO Management ReviewsX1.14Is there a continualimprovement plan applicableto each process defined in thescope of the assessment?The plater shall define a process for continualimprovement for each plating process identified inthe scope of the PSA. The process shall be designedto bring about continual improvement in quality andCapital/Continuous Improvements Logproductivity. Identified actions shall be prioritized andshall include timing (estimated completion dates).The plater shall show evidence of programeffectiveness.X1.15Does the Quality Manager ordesignee authorize thedisposition of material fromquarantine status?The Quality Manager or designee is responsible forauthorizing and documenting appropriate personnelto disposition quarantine material.Hold Area LogX1.16There shall be procedures and work instructionsavailable to plating personnel covering the platingprocess. These procedures or work instructions shallAre there procedures or workinclude methods of addressing potentialinstructions available toemergencies (such as power failure), equipment startplating personnel that defineup, equipment shut-down, product segregation (Seethe plating process?2.8), product inspection, and general operatingprocedures. These procedures or work instructionsshall be accessible to shop floor personnel.Work Instructions,Bar Tags,Electronic Plating Recipes,Suspect Load Procedure,Electronic QA Hold ProcedureX1.17The plater shall provide employee training for allplating operations. All employees, including backupand temporary employees, shall be trained.Documented evidence shall be maintained showingIs management providingthe employees trained and the evidence shall includeemployee training for plating?an assessment of the effectiveness of the training.Management shall define the qualificationrequirements for each function, and ongoing orfollow-up training shall also be addressed.Job Descriptions,Skill / Training Matrix,Training RecordsX1.18Is there a responsibility matrixto ensure that all keymanagement and supervisoryfunctions are performed byqualified personnel?The plater shall maintain a responsibility matrixidentifying all key management and supervisoryfunctions and the qualified personnel who mayperform such functions. It shall identify both primaryand secondary (backup) personnel for the keyfunctions (as defined by the plater). This matrix shallbe readily available to management at all times.Job DescriptionSkill / Training MatrixX 2012 AIAG (Automotive Industry Action Group)XNotSatisfactoryNeeds ImmediateAction
CQI-11Special Process: Plating System AssessmentVersion 2 Issued 2/2012Special Process: Plating Process Assessment (General Facility s there a preventivemaintenance program? Ismaintenance data beingutilized to form a predictivemaintenance program?Requirements and GuidanceObjective EvidenceN/ASection- ManagementThe plater shallhave a 1documentedpreventive Responsibility and Quality Planningmaintenance program for key process equipment (asidentified by the plater). The program shall be aclosed-loop process that tracks maintenance effortsfrom request to completion to assessment ofeffectiveness. Equipment operators shall have theopportunity to report problems, and problems shallPreventive Maintenance Schedule (Truealso be handled in a closed-loop manner. CompanyChem)data, e.g., downtime, quality rejects, first timethrough capability, recurring maintenance workorders, and operator-reported problems, shall beused to improve the preventive maintenanceprogram. Maintenance data shall be collected andanalyzed as part of a predictive maintenanceprogram.Has the plater developed acritical spare part list and are The plater shall develop and maintain a critical sparethe parts available toparts list and shall ensure the availability of suchminimize productionparts to minimize production disruptions.disruptions? 2012 AIAG (Automotive Industry Action Group)Production Critical ListSatisfactoryXXNotSatisfactoryNeeds ImmediateAction
CQI-11Special Process: Plating System AssessmentVersion 2 Issued 2/2012Special Process: Plating Process Assessment (General Facility nts and GuidanceObjective EvidenceN/ASatisfactorySection 1 - Management Responsibility and Quality PlanningSection 2 - Floor and Material Handling ResponsibilityDoes the facility ensure thatthe data entered in thereceiving system matches theinformation on the customer'sshipping documents?Documented processes and evidence of complianceshall exist, e.g., shop travelers, work orders, etc. Thefacility shall have a detailed process in place toresolve receiving discrepancies.Discrepancy Report,Routing Tags,Incoming Inspection LogX2.2Is product clearly identifiedand staged throughout theplating process?Procedures for part and container identification helpto avoid incorrect processing or mixing of lots.Appropriate location and staging within the facilityalso help to ensure that orders are not shipped untilall required operations are performed. Customerproduct shall be clearly identified and stagedthroughout the plating process. Non-plated, inprocess, and finished product shall be properlysegregated and identified. All material shall bestaged in a dedicated and clearly defined area.Routing Tags,Bar Code Tags,MF Labels,Rework Labels,Partial Container Labels,Scrap TagsX2.3Out-going lot(s) shall be traceable to the incomingIs lot traceability and integrity lot(s). The discipline of precisely identifying lots andmaintained throughout alllinking all pertinent information to them enhances theprocesses?ability to do root cause analysis and continualimprovement.Routing Tags,Incoming Inspection Log,Bar Code Tags,Electronic load tracking records,MF LabelX2.4Are procedures adequate toprevent movement of nonconforming product into theproduction system?The control of suspect or non-conforming product isnecessary to prevent inadvertent shipment orcontamination of other lots. Procedures shall beadequate to prevent movement of non-conformingproduct into the production system. Procedures shallexist addressing proper disposition, productidentification and tracking of material flow in and outof hold area. Non-conforming hold area shall beclearly designated to maintain segregation of suchmaterial.Hold Tags,Rework Tags,Scrap Tags,Hold Area LogX2.5Is there a system to identifyand inspect trap points in theentire plating process toThere shall be a list of trap points and workreduce risk of mixed partsinstructions detailing inspection frequencies.(inappropriate, unfinished, orimproperly plated parts)?Process Trap Points Sheet,***Training RecordsXProcedure for inspection of containersbefore use,Training RecordsX2.12.6Are containers free ofinappropriate material?Containers handling customer product shall be freeof inappropriate material. After emptying and beforere-using containers, containers shall be inspected toensure that all parts and inappropriate material havebeen removed. The source of inappropriate materialshall be identified and addressed. This is to ensurethat no nonconforming plating parts or inappropriatematerial contaminate the finished lot.2.7Is part loading specified,documented and controlled?Loading parameters shall be specified, documentedand controlled. Examples include parts per rack andload size.Picto-Structions,Part tags,Bar tags,MasterTracker Electronic SystemXAre operators trained inmaterial handling,containment action andproduct segregation in theevent of an equipmentemergency including powerfailure?Unplanned or emergency downtime greatly raisesthe risk of improper processing. Operators shall betrained in material handling, containment action, andproduct segregation in the event of an equipmentemergency including power failure. Training shall bedocumented. Work instructions specificallyaddressing potential types of equipmentemergencies and failures shall be accessible to andunderstood by equipment operators. Theseinstructions shall address containment/reaction plansrelated to all elements
CQI-11 Special Process: Plating System Assessment Version 2 Issued 2/2012 Question Number Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory Needs Immediate Action 1.1 Is there a dedicated and qualified plating person on-site? To ensure readily available expertise, there shall be
Iron, zinc plating 2 E3C-S50 (8) E39-L40 Iron, zinc plating 1 Phillips screws M4 25 (with spring and plain washers) Iron, zinc plating 2 E3JK Nuts M4 Iron, zinc plating 2 E39-L41 Iron, zinc plating 2 Phillips screws M3 14 (with spring washers) Iron, zinc plating 4 6 E3C-1 (10) Plain washer M3 Iron, zinc plating 4 E39-L42 Iron, black coating 2
PLATING INCONSISTENCIES include variations in plating thickness, degree of oxide contamination in the plating and the type of plating. Proper control of workpiece plating reduces the chance of weak or inconsistent welds and/or electrode sparking or sticking to the workpieces. Electroplating is much preferred over electroless plating.
PLATING INCONSISTENCIES include variations in plating thickness, degree of oxide contami-nation in the plating and the type of plating. Proper control of workpiece plating reduces the chance of weak or inconsistent welds and/or electrode sparking or sticking to the workpieces. Electroplating is much preferred over electroless plating.
Copper plating tank, IF Cadmium plating tank - ventilated Zinc automatic rack plating line Zinc plating tank . . . . . . . Acid cleaning line and exhaust hood Side view of acid hood and tank Tank 7H - acid etch . . . . Caustic cleaning tank with cover . . . Solvent degreaser with cover open viii 52 53 53 54 61 64 68
Zinc-Nickel Alloys What is Best Ni Composition in Zinc-Nickel Plating? - 4 to 18% Appears to Give Good Corrosion Resistance and Sacrificial Protection to Steel - High % Ni Appears to Create a Non-Embrittling Plating Process What is Best pH for Zinc-Nickel Plating? - Alkaline Plating Appears to Be Easier to Use Bath Easier to Maintain
Plating Structure Sn plating thickness 0.8 µm 0.3 µm IMC thickness 0.4 µm 0.3 µm Ni substrate plating thickness － 0.5 µm Reflow treatment Applied Applied Reduction effect for Coefficient of friction － 20% Sn Coppe r Alloy IM C（ u-Sn） Sn Coppe r Alloy IMC（Cu-Sn） Ni Conventional plating structure Ideal structure of low friction .
The plating rack held 16 pieces and could be run in two different configurations. If all the plating locations were shorted together, the rack simulated a traditional plating rack. If each conductor was controlled individually, this represented the Smart Rack technology. Figure 3 shows the width of the plating thickness dis-
compliant plating treatment A full list of available plating options and properties for ITT's key metal product lines Proprietary Blue Generation Plating for the Toughest Industrial Applications Our engineers developed Blue Generation zinc nickel plating, which delivers both RoHS and REACH compliance and outstanding performance.
