AIAG 2 Automotive Industry Action Group CQI-9 Special Process: Heat Treat System Assessment 3" EditionJS IIS II, cccgocooogaogc LCCOCCCOCLCCCCCCCAIAG a gas Special Process: Heat Treat System Assessment ‘Tha cata for peak prormane ‘Version 3, Issued 10/2011 ABOUT AIAG Purpose Statement Founded in 1982, AIAG is a globally recognized organization where OEMs and suppliers unite to address. and resolve issues affecting the worldwide automotive supply chain. AIAG's goals are to reduce cost and ‘complexity through collaboration; improve product quality, health, safety and the environment; and, optimize speed to market throughout the supply chain AIAG Organization AIAG is made up of a board of directors, an executive director, executives on loan from member companies, associate directors, a full-time staff, and volunteers serving on project teams. Directors, department managers, and program managers plan, direct and coordinate the association's activities under the direction of the executive director. AIAG Projects Volunteer committees focus on business processes or supporting technologies and methodologies. They conduct research and develop, publish, and provide training on standards, conventions, standard business practices, white papers, and guidelines in the areas of automatic identification, CAD/CAM, ED\electronic commerce, continuous quality improvement, health focus, materials and project management, occupational health & safety, returnable containers and packaging systems, transportation/customs and truck & heavy equipment. ‘AIAG PUBLICATIONS ‘An AIAG publication reflects @ consensus of those substanlaly concemed with ts scope and provisions. An ‘AIAG publication is intended as a guide to aid the manufacturer, the consumer, and the public. The existence of ‘an AIAG publeation does not i any respect preclude anyone from manufacturing, marketing, purchasing, or Using products, processes, o procedures not conforming tothe publication. (CAUTIONARY NOTICE [AIAG publications are subject to periodic review and users ar cautioned fo obtain the latest edtions. MAINTENANCE PROCEDURE Recognizing that this AIAG publication may not cover all creumstances, AIAG has established a maintenance ‘procedure, Ploase refer o tho Maintenance Request Form at he back of tis document fo submit a request. Published by: Automotive Industry Action Group "26200 Lanser Road, Suite 200 ‘Southfield, Michigan 48033 Phone: (248) 356-2870 » Fax: (248) 358-3253 APPROVAL STATUS ‘The AIAG Qualiy Steering Committe and designated stakeholders approved this document fr pubicstion in October 2011 AIAG COPYRIGHT AND TRADEMARK NOTICE: ‘The Automotive Industry Action Group copyrights the contents ofall published materials unless otherwise indloated. Copyright fs not Claimed as to any part of an orginal work prepared by a U.S. or state government officer or employee as pat ofthe person's oficial ‘hits. Ail rights are preserved by AIAG, and contant may not be alered or disseminated, putilshed, or ransferred In part of such Content. The Information isnot fo be sold in pat or whole o anyone within your organization orto another company. Copyright Intingement isa violation of federal law subjec o criminal and civl penalties. AIAG and the Automotive Industry Acton Group are ragistored service marks ofthe Automotive Industy Action Group. (© 2011 Automotive Industy Action Group 1900: 9 781 60534 2368cone AIAG Specil Process: Hoat Treat Systom Assessment Pp Version 3, Issued 10/2011 Tho cata! er paak prfamanceAIAG pais Special Process: Heat Treat System Assessment The catalyst for peak partormance Version 3 Issued 10/2011 FOREWORD Automotive Industry Action Group (AIAG) committees are made up of volunteers from member ‘companies in the automotive industry. The work of preparing process audits is done by AIAG technical committees. ‘The main task of technical committees is to prepare automotive standards and system requirements, Draft documents adopted by the technical committees are circulated to the Steering Committee for review and consensus approval. Publication of the documents requires approval by the Quality Steering Committee. ‘The Quality Steering Committee would like to acknowledge and thank the following individuals and their companies who have contributed time and effort to the development of this document. Philip Mikula (CQI-9 Chairperson) — TRW Automotive, Inc. Dean Higdon ~ Acument Global Technologies North America Pete Batche ~ Akebono Brake Corporation, North America Stefan Bruder — Bodycote Warmebehandlung GmbH ‘Madhu Chatterjee ~ Bodycote Thermal Processing, North America Rick Howell —Chrysler Group LLC, North America Darrell Rydzewski — Controls Service, Inc. Virender Choudhri — Delphi Corporation Stephen Toltesi ~ Eaton Corporation ‘Suranjeeta Dhar ~ Ford Motor Company Peter Schiefer ~ Ford Motor Company, Germany Medina Kaknjo ~ Ford Motor Company Rick Metcalf ~ General Motors Company, North America David Paluch — General Motors Company, North America Werner Schwan ~ Robert Bosch GmbH Germany Jeff Martin - ZF Friedrichshafen, AG Luiz. Tubino ~ LC Desenvolvimento Empresarial LTDA, Brasil Kevin Bauer ~ Keystone Powdered Metal Company Delbert Clubine, Advance Heat Treat Corporation,gas AIAG Special Process: Heat Treat System Assessment | Version 3, Issued 10/2011 The cata! for pesk performance CHANGES TO CQI-9 3*° EDITION ‘The Special Process: Heat Treat System Assessment, 3” edition contains some new requirements, changed requirements, and clarifications that the supply organization will need to consider in making its self-assessment. This 3" edition is collaborative work of OEM, Tier | suppliers, heat treat suppliers, and calibration companies that service the heat treat industry. Below is a summary of the important changes in this 3° edition. 1, Three new Process Tables have been added: ‘© Low Pressure Carburizing © Sinter Hardening © Ton Plasma) Nitriding 2, The format and layout of the Process Tables have been improved to facilitate the heat treat system assessment, 3, References to AMS 2750D have been removed and replaced with AIAG CQL-9 specific requirements. 4, Frequency for SAT and Instrument Calibration have been changed. The requirement in the 3% Edition allows the heat treater to choose one of the two following options: Option 1: Quarterly SAT (Probe Method A or B) or Monthly SAT (Comparative Method), and Quarterly Control Instrument Calibration (single-point or multi-p calibration) Option 2: Quarterly SAT (Method A only) and Semi-Annual Control Instrument Calibration (multi-point calibration; 1-point calibration not allowed with semi- annual frequency). 5. The 3 Edition allows two options for the frequency for calibrating oxygen probe controllers (used in carbon-bearing atmospheres): ‘© Quarterly (single-point calibration or multi-point calibration is allowed) ‘+ Semi-annual (multi-point calibration method; single-point calibration is not allowed) 6. Frequency for checking the quench oil cooling curve was changed to semi-annual (2 Edition required quarterly frequency checks). 7. The temperatures given in °C and °F were harmonized. That is, the direct conversion from °C to °F is not used but rather the common tolerances for °C and °F were used. For example, the TUS tolerance for carburizing furnaces is + 15 °C (+ 25°F). Questions 1.20, 3.20, and 3.21 were added to the CQI-9 Heat Treat System Assessment, 9. Question 1.11 was modified. This question addresses re-processing procedures. 10. Question 3.7 ~The oxygen probe controller (carbon controller) shall control the carbon potential + 0.05%. 11. Question 3.12 was modified. This question addresses the proper height of the workload on a continuous belt furnace.AIAG» at res eat Tat yon sacl The catatferpoakpatomance Version 3, lssued 10/2014 TABLE OF CONTENTS ‘ABOUT AIAG. FOREWORD ssosnnsnn ‘TABLE OF CONTENTS INTRODUCTION. GENERAL sone PROCESS APPROACH nnn Heat TREAT SrsTeM ASSESSMENT GOALS ASSESSMENT PROCESS. ‘ASSES80R QUALIFICATIONS (OTHER REQUIREMENTS... SCOPE se 1.4 Genera 1.2 APPUCATION.... 1.3 Rerenence. 2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE 3 SPECIAL PROCESS: HEAT TREAT ASSESSMENT... 3.1 TaeRMoCOUPLES 3.2 INSTRUMENTATION. 3.3 SYSTEM ACCURACY TEST (SAT) nes 3.4 TempeRaTuRe Untrortay SuRvers (TUS) [APPENDIX A ~ PROCESS TABLES. PROCESS TABLE A: CARBURIZING / CARBON CORRECTION / NEUTRAL HARDENING / AUSTEMPERING / MARTEMPERING / TEMPERING / PRECIPITATION HARDENING - AGING. PROCESS TABLE 8; NITRIDING (GAS) AND FERRITIC-NITROBARBURIZING (GAS OR SALT) PROCESS TABLE C: ALUMINUM HEAT TREATMENT. PROCESS TABLE D: INDUCTION HEAT TREATING .... PROCESS TABLE E: ANNEALING / NORMALIZING / STRESS-RELIEVING .. PROCESS TABLE F: LOW PRESSURE CARBURIZING. PROCESS TABLE G: SINTER HARDENING. , PROCESS TABLE H: ION NITRIDING GLOSSARY.cal-9 Sn AIAG ‘Version 3. Isued 1072011 The ctayst for peak perfomanceAIAG.» cal-9 Special Process: Heat Treat System Assessment ‘Tra cata pookparermarce ‘Version 3, Isued 10/2011 INTRODUCTION General ‘The work of preparing CQI 9: Special Process: Heat Treat System Assessment (HTSA), Third Edition, ‘was carried out through the AIAG Heat Treat Work Group. These heat treat requirements are complementary to customer and product standards. ‘The HTSA can be used to assess an organization's ability to meet the requirements in this assessment, as, well as customer, regulatory, and the organization’s own requirements. The HTSA can also be used between an organization and its suppliers. In the HTSA, the word “shall” indicates a requirement for purposes of the self assessment. Failure to meet the requirements results in an assessment that is either “Not Satisfactory” or “Needs Immediate Action”. The word “should” indicates a recommendation. Where the term ‘such as” is used, any suggestions given are for guidance only. Process Approach The TSA supports the automotive process approach as described in ISO/TS 16949, Heat Treat System Assessment Goals ‘The goal of the HTSA is the development of a heat treat management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain. ‘The HTSA, coupled with an internationally recognized quality management system and applicable ccustomer-specific requirements, defines the fundamental requirements for heat treat management systems. ‘The HTSA is intended to provide a common approach to a heat treat management system for automotive production and service part organizations. Assessment Process Ongoing assessments shall be conducted, at a minimum, annually, unless otherwise specified by the customer, to ensure continuous compliance with the HTSA. Each assessment shall include a review of the organization’s systems using the HTSA. Successive Job Audits (Section 4.0 of this document) shall sample parts from different automotive component manufacturers that require compliance to the HTSA document. ‘The assessment shall use the process approach to auditing as identified by the requirements of ISO/TS, 16949,gone AIAG Special Process: Heat Treat System Assessment Version, sued 10/2011 Tho catalyst for peak performanca Use of CQI-9, HTSA, and Proc bi CQI-9 HTSA and Process Tables address the most common thermal processes employed by the automotive industry. Due to the vast differences in the various thermal processes currently available, it may be necessary to incorporate requirements across the provided process tables. ‘The assessor has the availability to employ requirements from multiple Process Tables if an element of the thermal process being assessed requires such. Assessor Qualifications Assessor(s) shall have the following specific experience to conduct the HEAT TREAT SYSTEM ASSESSMENT: 1, Be an experienced quality management system (QMS) internal auditor (for example, ISO/TS 16949, ISO 9001) 2. Assessor shall possess heat treating knowledge. Evidence shall include a minimum of 5 years experience in heat treating or a combination of formal metallurgical education and heat treating experience totaling a minimum of 5 years. 3. Assessor shall possess knowledge of and be familiar with the application of automotive quality core tools including statistical process control, measurement systems analysis, part approval, failure mode and effects analysis, and advanced quality planning. ‘Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in item #1 Other Requirements ‘The organization shall keep records as evidence of compliance to the requirements identified in the HTSA, ‘as well as all appropriate action plans to address any unsatisfactory ratings. These records shall be readily available for review by any customer requiring compliance to the requirements within this document. Documentation recovery shall meet TS16949 or ISO 9001 requirements for process control and inspection records.AIAG cals Special Process: Heat Treat System Assessment The cata for pask prtorancs Version 3 Issued 10/2011 1 SCOPE 1.1 General This document specifies process requirements for an organization or its suppliers performing applicable heat treating, who need to: ‘© demonstrate ability to consistently provide product that meets customer and applicable regulatory requirements, and ‘* enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system. The Heat Treat System Assessment is applicable to sites where customer-specified parts for production and/or service are processed throughout the automotive supply chain. 1.2 Application All requirements of the HTSA are generic and are intended to be applicable to all organizations performing the heat treat operations addressed in this document, regardless of type, size, and product. Eight Process Tables have been developed and the appropriate table(s) is to be referenced during the assessment. The Process Tables are specific to heat treat processes as noted below: Process Table A ~ Ferrous . Carburizing . Carbonitriding . Carbon Restoration ot Correction . ‘Neutral Hardening (Quench and Temper) . Austempering . Martempering . ‘Tempering, . Precipitation Hardening — Aging Process Table B~ Ferrous . Nitriding (Gas) . Ferritic-Nitrocarburizing (Gas or Salt) juminum . Aluminum Heat Treating Process Table D Ferrous . Induction Heat Treating Process Table E - Annealing, Normalizing, and Stress-Relieving ® Conformance to CQI-9 is required for all organizations that perform annealing, normalizing, or stress-relieving to achieve desired final characteristics of the part. Process Table F ~ Low Pressure Carburizingcal-9 Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 AIAG.» The catalyst for pak prtomsnce Process Tabk = Sinter Hardening Process Table H — Ion Nitriding Note: Material producers of primary or raw materials, or any intermediate thermal treating process step(s) that do not affect the final characteristics of the part are exempt from conforming to the requirements in CQL. ‘These Process Tables contain requirements for: Process and Test Equipment Pyrometry 1 2, 3. Process Monitor Frequencies 4, In-Process/Final Test Frequencies 5. Quenchant and Solution Test Frequencies ‘The Process Tables specify the tolerances of process parameters and the frequencies for checking process control parameters and parts. The requirements and guidance in the HTSA form will notify the assessor when to refer to the Process Tables. 1.3 Reference The following standards are referenced in this document. The applicability is limited to the subject matter referenced. Sen Mg at RCE az n ISO/TS16949 ‘Quality management systems ‘Intemational Organization for _ - Standardization ISO/IEC General Requirements for the Intemational Organization for competence of testing and Standardization calibration laboratories 180 9001 Quality management systems Intemational Organization for requirements Standardization TEC 60584-1 ‘Thermocouples Reference Tables | International Electrotechnical Commission ‘ASTM E230 Standard Specification and ‘American Standards of Testing and ‘Temperature-Electromotive (EMF) for Standardized Thermocouples -10- MethodsAIAG a cus ‘Special Process: Heat Treat System Assessment Tho cata for pask pertormarco Version 3, Isued 10/2011 2 THE HEAT TREAT SYSTEM ASSESSMENT PROCEDURE Obtain current copy of CQI-9 Special Process: Heat Treat System Assessment, 3rd edition from AIAG. 2. Identify all heat treat processes to which CQI-9 Special Process: Heat Treat System ‘Assessment, 3rd edition applies (see CQI-9, 1.2 Application). Record these processes on the HTSA, Page | 3. Complete the HTSA, determining the level of compliance. A minimum of one job audit (Section 4) shall be performed during each assessment. 4, Address each “Not Satisfactory” item and determine corrective action, including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. 5. “Needs Immediate Action” requires immediate containment of suspect product. Address each “Needs Immediate Action” item and determine corrective action(s), including root cause analysis and implementation of the corresponding corrective action(s). The corrective action(s) shall be completed within 90 days. Records of the corrective action, including verification, shall be maintained. 6. Assessments shall be conducted annually unless otherwise specified by the customer.“12. cal-9 Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 Tho catalyst er pask performanceAIAG» rosner ‘Special Process: Heat Treat System Assessment The cata fr peak perormancs “Version 3, Issued 10/2011 3 SPECIAL PROCESS: HEAT TREAT ASSESSMENT INSTRUCTIONS FOR COMPLETING THE COVER SHEET COVER SHEET FORM. INSTRUCTIONS FOR COMPLETING SECTIONS 1-3 SECTION 1: MANAGEMENT RESPONSIBILITY & QUALITY PLANNING ‘SECTION 2: FLOOR AND MATERIAL HANDLING RESPONSIBILITY .. SECTION 3: EQUIPMENT.. INSTRUCTIONS FOR COMPLETING THE JOB AUDIT... SECTION 4: JOB AUDIT FORM.“14 caus AIAG Special Process: Heat Treat System Assessment P Version 3, Iued 10/2011 Tha ctayt fer peak perfomance Instructions for completing the Cover Sheet 1 10. 1B. Facility Name: Name of the facility being assessed. ‘One form shall be used for each facility, The facility may have several buildings or physical locations in the same general area. If there is a separate management team (Quality Manager and Metallurgist) or different management system, then these locations shall be considered as separate facilities. Address: The street address of the facility being assessed; P.O. Box numbers may be given as additional information. Phone Number: The phone number of the facility. If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used, Fax Number: The fax number of the facility. Number of Heat Treat Employees at this Facility: The number of employees, salaried and hourly, associated with the heat treat operation at this facility, Captive Heat Treater (Y/N): Enter “Y" if this facility heat treats components for their own company. Enter “N” if the company does not heat treat any components for their own company. Commercial Heat Treater (Y/N): Enter “Y” if this facility heat treats components for ‘companies other than their own company. Enter “N” if this facility does not heat treat any ‘components for other companies. Date of Assessment: Enter the date(s) of the assessment, An alphanumeric format shall be used to avoid confusion with different numeric formats, Example: May 3 ~ 4, 2011 Date of Previous Assessment: List the date of the previous CQL-9 Special Process: Heat Treat System Assessment of this facility. ‘Type(s) of Thermal Processing at this Facility: Place a checkmark to designate all thermal process(es) performed at this facility. This information determines the appropriate Process Table that shall be used during the assessment. Processes not listed on the cover sheet are not part of the Heat Treat System Assessment. Current Quality Certification(s): The heat treater shall list their current quality certifications, €.g,, ISO/TS 16949, ISO 9001. Certifications may be from 3rd party sources or customer quality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given. Date of Re-assessment (if necessary): If “Not Satisfactory” findings were observed from the original assessment, then the heat treater shall address each item and determine correct action, including root cause analysis and implementation of the corresponding corrective action(s). ‘The date of the re-assessment shall be given here, and the appropriate Question(s) from Sections 1 —4, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the “Number of Not a stiall be aiodified as appropriate, Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available, of the principal participants from the heat treater’s organization.ERRATA SHEET FOR CQI-9 Special Process: Heat Treat System Assessment, 3° EDITION 4) Figure 3.4.1 ~ The 12 thermocouple locations in the cylindrical furnace is changed to 9 thermocouple locations as shown below. © Represents thermocouple locations 2) Cover Sheet Form — typographical error on CD ‘0 The Header on the top right side should read, Version 3, Issued 10/2011. © Process Table G is listed twice and should read, « Process Table G — Sinter Hardening «Process Table H — lon Nitriding ‘©. Directions for correction typographical error on CD: + When using the CD the first time, save the file to your computer * From the Cover Sheet, click on Page Layout tab, click the arrow in the bottom right comer of the Page Setup group to display the Page Setup dialog box * Click on Header/Footer tab and select the Custom Header button "Change to Version 3, Issued 10/2011, click OK. * Locate cell C- 40, change Process Table G to Process Table H 3) Process Table E ~ Annealing / Normalizing Stress Relieving ~ 4.1 changed as shown below. AIAG Errata Sheet for CQI-9 3” Edition Issued Jan. 2012, Updated April 2012 www aiag.org4) Process Table G ~ Sinter Hardening; G3.1, The Process Monitor Frequencies for Atmosphere Generation was corrected as shown below (red circles). “4 JMontor primary temperature 2.14 Jeontel instruments) [Continuous recording jth sign-off every 2 Jnours or each bath for [Continuous recording Ono ofthe tree options requires. hours or each lt for (1) Record termperature 2x por iland ater any change, (2) Comnuously record lempecre and graf x pe shit and after any change. 9) Alarm system on liemparature contro. NOTE: G4.5 1S DELETED AND REPLACED BY G4. 5) Process Tables A, B, and G — Microstructure PROCESS TABLE A ~ Carburizing / Carbonitriding / 1 AS SHOWN ABOVE. inspection frequency changed to below. Carbon Restoration / Neutral Hardening / Austempering/Martempering/Tempering/Precipitation Hardening — Aging Bat [Paly per fmace unless. |specited by customer tobe Jchecked with grater |requency, e.g. each batch. Daly per Rmace uniess specified by customer to be [checked wih greater [Feauency, eg, each batch, PROCESS TABLE B ~ Nitriding (Gas) and Ferritic-Ni “14 [Microstructure shall be checked at a minimum 2.15 magniteation of 100 and, 400% or above 40x |wicrostructural visual references shall be availabe, itrocarburizing (Gas or Salt) JOaiy per mace ures [spocited by customer to be Jonecked with greater [requency,e.. each batch. ally por mace unl |spocited by customer to be Jchacked with greater Frequency, e.., each batch, PROCESS TABLE G — Sinter Hardening “14 [Microstructure shal be checked at a minmum 2.15 magnieation of 100 and, £00% or above 400% {uicrostuctural visual references shall be aalable [Daly per mace unless lspecid by customer tobe |spected by customer to bo Jcnecked with greater |chooked with greater [requency, e.g, each baton. frequency, e.g. each batch 8) Process Table D - D4.2 typographical error changed as shown below. D2} 14 Total or Eiecive Case depth [part at start-up, end of production run, and 1 part perB 218 hours minimum, and + part pre and 1 pat post too! Jcnange. equipment repair, station alarm (shutdown, |matuncton, ete), AIAG Errata Sheet for CQI-9 3” Esltion Issued Jan. 2012, Updated April 2012 wn aiag orgERRATA SHEET — Items 7 through 10 were added April 2012 to Errata Sheet released January 2012 7) System Accuracy Test referenced in Table item #’s: A2.3, 82.3, C2.3, E2.3, F2.3, and 62.3. Current reading: CQI-9 requires a System Accuracy Test (SAT) check of the control thermocouple in the Qualified Work Zone per Section 3.3 New reading: CQI-9 requires a System Accuracy Test (SAT) check of all control thermocouple per Section 3.3. Also, any recording or monitoring thermocouple(s) more than 5 centimeters from the controlling thermocouple in the zone, for example thermocouples in continuous belt furnaces near the drop point to quench used for recording or monitoring the hardening temperature (this does not include the “over- temperature” thermocouples that are used to protect the furnace from overheating). 8) Change Glossary definition of “Resident Thermocouple’ to: A test thermocouple that is not removed from its test location, and is used for the SAT Comparative Method. The resident thermocouple shall meet the requirements of Section 3.3.4.3 and Table 3.3.1. AIAG Errata Sheet for CQl-9 3" Edition Issued Jan, 2012, Updated April 2012 www.aiag.org9) Illustrations 3.3.1 (page 50), 3.3.2 (page 52), and 3.3.3 (page 54) were not labeled. The temperatures in the graphics did not match the temperature values in the Example. These corrections are show below. Example of Probe Method "A" pee ON Over-Temp Protection Part or Raw Material A Test Furnace ‘Thermocouple Furnace Wall Workzone (2) Test Instrument Lead Wire ILLUSTRATION 3.3.1 EXAMPLE OF ACCEPTABLE SYSTEM ACCURACY TEST (SAT) PROBE METHOD - A oa TEST - RUE TEST Date i TRUE T e li eda ZnCl) FACTOR re, p 3) ere Cech. ee 00° 901.5% 08°C +0.1°C 901.1°C AAC (1652"F) (1655°F) (10°F) (902°) (1654.2°F) (22°F) AIAG Errata Sheet for CQI-9 3 Edition Issued Jan, 2012, Updated Apri 2012 www.lag.orgExample of Probe Method "B" Settle Controt Thermocouple he ‘Over-Temp Protection Part or Raw Material Furnas WorkZone (A) Test Instrument ILLUSTRATION 3.3.2 EXAMPLE OF ACCEPTABLE SYSTEM ACCURACY TEST (SAT) PROBE METHOD - B ere SAT Presa rag Sas Wi t G eT re aa Sam x oe S ean} 901.1°C. (1654.2°F) Note: Test instrument A and Test Instrument B are typically the same test instrument. AIAG Errata Sheet for CI-9 3" Edition Issued Jan, 2012, Updated April 2012 wwrw.alag.orgExample of Comparative Method Over-Temp Thermocouple Controt Thermocouple (A.D) Control instrument Over-Temp Protection Part or Raw Material Fumace Thermocouple Furnace Wall WorkZone {B.£)Resident Thermocouple Monitor ‘Note 4: Itis recommended that the comparative check be performed at or near the intial temperature at, the time of instrument calibration (See A & B temperature in example below). Note : Resident thermocouple and over-temp thermocouple may be the same thermocouple ILLUSTRATION 3.3.3 EXAMPLE OF ACCEPTABLE SYSTEM ACCURACY TEST (SAT) COMPARATIVE METHOD Perc inary ome Pech e earth BE ea Coen Cena imme) ie Pence eta NTN OEE) roy AIAG Errata Sheet for CQI-9 3" Edition Issued Jan. 2012, Updated April 2012 ‘wwnw.aiag.org10) Process Table C, Item #C2.4 states minimum and maximum temperature shall be “defined” “Defined” should be replaced with “tested” as shown below. CEA] 24 [Temperate Unity Suny (US) TUS Foquncy shal be quarry and aor mojr bul por Sooton 37 |remperatce Ui ta [Temperature Unio tk ce for elton and aging fanaces sal bo #- 5° (+ 10°F, nce for nea farce shal bef 158 (6-257) Jtrimum and maxim temperature of ihe operating rnge shal be estes. Exception: tthe operating range ofthe [autos vor Zae sequal oo iss than 85° (155) then onl oe tempera is equa tobe lated. The teat lomperture state wit the opaeing range ofthe Quked Wok Ze [For continuous Furnaces, this rquirement apples tothe Qualified Work Zone AIAG Errata Sheet for CQL 3" Edition Issued Jan, 2012, Updated April 2012 worw.aiag.orgAIAG 2m gas Special Process: Heat Treat System Assessment ‘Tow cata rook paramance Version 3, Issued 10/2011 14, Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), if available, of the auditor/assessor(s). 15, Number of “Not Satisfactory” Findings: Enter the number of “Not Satisfactory” findings observed during the assessment, 16. Number of “Needs Immediate Action” Findin; ‘Action” findings observed during the assessment. 17, Number of “Fait” Findings in the Job Audit(s): Enter the number of “Fail” findings observed from the job audit. inter the number of “Needs Immediate 15.-16- cal-9 Spel Process Het Test System Assent AIAG 2» Version 3 Issued 10/2011 Cover Sheet Form The catalyst or pook pertormance [Special Process: Heat Treat System Assessment iba Hoat Treat eeee a Tae ra (Capa Heal TSE, TERT HS TESTE Eo RETO I PRS Reese reno Ton ia assesment ncaa [lonber oT Tot Sarena” FIGS SNES uanborot Fal Figs inthe Job Ad pot Tera Procesting as Fas ae jaueneh & Tener [ustrngeng Maran Icing ose Fer rocone Tam seas Tab DFO [nition Heat Tre [Ser RarerAIAG 2m cals Special Process: Heat Treat System Assessment Tho cata forpaok pertormance Version 3 Issued 10/2011 Instructions for completing Sections 1-3 Sections 1 - 3 contain questions and the requirements and guidance for each question. The Sections are: ‘* Section 1 ~ Management Responsibility & Quality Planning * Section 2 — Floor and Material Handling Responsibility * Section 3 Equipment ‘The assessor shall assess the heat treater’s compliance to Sections 1 ~3 by comparing the evident presented by the heat treater to the requirements listed in the “Requirements and Guidance” column, NOTE: Inthe “Requirements and Guidance” column, the word “shall” indicates aa requirement and the term ‘such as” indicates that any suggestions given are for guidance only. NOTE 2: ‘The “Requirements and Guidance” column will indicate to the assessor when the Process Tables are pertinent to the questions. When the Process ‘Tables are pertinent to the question, the assessor shall assess the heat treater’s compliance to the specified section(s) in the Process Tables. NOTE3: If the question is not applicable to the heat treater, then the assessor shall place a checkmark in the “N/A” Assessment column, If the observed evidence is in compliance to the question, the assessor shall note the evidence in the “Objective Evidence” column and place a check mark in the “Satisfactory” column. If the observed evidence is not in compliance to the question, then the assessor shall note the non-compliance in the “Objective Evidence” column and place a check mark in the “Not Satisfactory” column. NOTE 4: Where nonconforming product is identified in the assessment of a given question the assessor shall place a check mark in the “Needs Immediate ‘Action” (NIA) column, NIA requires immediate containment of suspect product. “WeThe catalyst for peak porerance ‘Special Process: Heat Treat System Assessment Section 1: Management Responsibility & Quality Planning Version 3, Issued 10/2011 cal-9 os ane mg | mp nro ana lace] SEEM | coxsennes [un wp a0 WOUISEOSsy WIsAS JEO1] JOH :=sBIIG [eIDOdS -18-cal-9 ‘Special Process: Heat Treat System Assessment Version 3, issued 10/2011 The catalyst for peak pertormsneo AIAG» -19- Jvpscnasosou| ene | Snes |v baps-acbeahi con quauissossy wiaysAs veal] POH :ss0901d 1eIo0ds‘The cata forpaak parormance xno eo sompng pu nususybn yourssossiy worsAs B01) JOH 285200%4 jerseds, Special Process: Heat Treat System Assessment Version 3 Issued 10/2011 cal-9 -20-cal-9 Version 3, Issued 1072011 “ese wp sep en cor wom sake put Special Process: Heat Treat System Assessment sooesaes |v empua enpetan pump pur swoussnba onsen sawn ‘hopepnes = ‘The cata for posk pertomancs qwewssessy wo}s%g eal] Wea} 'sse001g ereds, -2l-Tho catayt for peak perfomance AIAG» Special Process: Heat Treat System Assessment Version 3, lssued 10/2011 cal-9 2voinone Su wena noe stetsene fury quouissessy wo}sKs ye01 JBOH :Ss990N4 [8120s 2cal-9 son 3, Issued 10/2011 Ver rp anna tne] cayman se Bape po] aumeene myers nboom Aw ma) Special Process: Heat Treat System Assessment omnes opamte ast aot eure pe seuaary ‘Tha cata for pak pertorance AIAGsumtin aceon ann oye aces pus peer me ep SEI ‘Tho catalyst for pesk perrmanca epee] SEE | corer vn opi ocea0 upng pu suswmining wowssossy WoISKs yall WeeH :sse0014 JeIDeds, Special Process: Heat Treat System Assessment Version 3 leued 10/2011 cal-9 24.cal-9 ‘Special Process: Heat Treat System Assessment ‘Version 3, Issued 10/2011 The cata fr poak prtoranca ‘oosennes = hooesars lym scapes essing yuauissassy WaySAg WON] EH :sse20I4 [eIDEdS 25-The estat for peak performance Section 2: Floor and Material Handling Responsibility Special Process: Heat Treat System Assessment Version 3 Issued 10/2011 cal-9 ent poner men oman “Suomen pina om orate] cman mee secers | cocceaes [yn] uma mo oun po ny a Weussossy uoish yeal| 69H ;9s80014 (ods 26-cal-9 ‘Special Process: Heat Treat System Assessment sion 3, tssved 10/2011 Ver AIAG ‘The cata for pookportaranca oy _ | Compan a uoulssessy walsh Wall OH :S5=9014 1.2045 ne esThe catalyst fr posk performance AIAG.» Special Process: Heat Treat System Assessment Version 3, Isued 1072011 cal-9 -28-cal-9 Special Process: Heat Treat System Assessment AIAG_a Version 3, Issued 10/2011 The cata for pss pertormance ee ee a |_—— Wuauissossy UusIsAs Waly IWaH :eseD01g feIoeds -29-Tho cata for Deak performance Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 cal-9 306cal-9 ‘Version 3, Issued 1072011 ‘Special Process: Heat Treat System Assessment quouissessy wiarsAs yal] 19H :=S0901g jeIDeds Section 3: Equipment Thecatayt fr peak perfomance AIAG ieTo catatyst or paok performance AIAG Special Process: Heat Treat System Assessment Version 3, Issued 1072011 cal-9 frve.slours tio sre wes xomiooy| ooeun pus cn ay Peau tc nce enema pewaunaop ogame opoye wie soa eps cypann eo Spe SO CC) ven dod Jesonmtectren ume | oe woonseee [yn supa atmsta0 od JUOWISSoSSy Wia}SKG yealy }eOH :Ss900I4 je1sads 32.cal-9 Version 3. 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Issued 10/2011 ‘Special Process: Heat Treat System Assessment "sou pon x ee ponatcese amma Srna rne purse gpa be ayepasinbs cum, Fowosreypecomera |e pec wipescn wee eon an feooseees | poems fun] sxmpuseanato cou po sna wooo = — quoussassy umShs war yeoH :ss090ug frseds Tho cata for peak performance -35-eenewope wopte uor> od seo Eaonned oo WUOWSSOSSy UIOISAS WAI] JOH sS9001g [eIDadS ‘Special Process: Heat Treat System Assessment Version 3 Isued 10/2011 caQl-9 -36-cal-9 ‘Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 AIAG ‘The cata for peak parormancs 37. po oped ps ope gel Sato emf vameadeal ag rojdrec conde usopodnegs menos us| esas pious S09 von. | Moen supp aetao oun pur ue onsin oe ace “EEE | kmcenaes [ym og a wow com {uowssossy woh W291] 19H :8s2001¢ [Bioodscal-9 Special Process: Heat Treat System Assessment Version 3, sued 1072011 The catalyst for peak performanceAIAG = ‘Special Process: Heat Treat System Assessment Tho cata for paokperormanco ‘Version 3. Issued 10/2014 3.4 Thermocouples 3.1.1 Application of Thermocouples: Thermocouples shall be selected as appropriate for their intended use, Where a process is to be controlled, consideration shall be given to variables that can have ‘an impact upon thermocouple performance such as, but not limited to, atmosphere, temperature, electrical interference, ete. Guidelines established for recommended temperature ranges ot uppet temperature limits for thermocouples in publications such as ASTM £230, IEC 60584-1, or other national standards or by the thermocouple manufacturer should be adhered to. 3.1.L.1 All thermocouples shall comply with Tables 3.1.1, 3.1.2, 3.1.3, 3.1.4 and 3.1.5 requirements. 3.1.1.2 Extension wire shall not be spliced. Only compensated jacks, plugs, connectors and terminal strips may be used. 3.1.2. Calibration of Thermocouples: Thermocouples shall be calibrated traceable to the National Institute of Standards and Technology (NIST) or other national institute of calibration, such as PTB (Germany). A grace period of 2 weeks is allowed for all calibrations. 3.1.2.1 Thermocouples shall be calibrated in the temperature range in which they will be employed and prior to first use. Calibration temperature intervals shall not exceed 150°C ot 250°F. Refer to Tables 3.1.1, 3.1.2, 3.1.3, and 3.1.4 for appropriate thermocouple calibration and replacement requirements. 3.1.2.2 Calibration certificates shall include the following detail: the actual test temperature reading, the nominal test temperature, the corresponding correction factor for each calibration temperature test point, the provider of the calibration data, and the calibration method used. 3.1.2.3 The interpolation of correction factor values between calibration test points is allowed. No determinations shall be made concerning values either above the highest calibration temperature or below the lowest calibration temperature. 3.1.2.4 Extemal sources providing calibrations shall be accredited to ISO/IECI7025 or other national equivalent. Internal sources providing calibrations shall do so in accordance with the intent of ISO/IEC17025 or other national equivalent. Records shall be kept of training and qualifications for internal personnel performing calibrations. 3.1.2.5 Thermocouples may be individually calibrated or made from calibrated rolls provided that both tends of the roll are sampled and the accuracy requirements established in Tables 3.1.1, 3.1.2, 3.1.3, and 3.1.4 ate satisfied. 3.1.3. Reuse of Thermocouples: The date that any thermocouple is placed in service shall be documented, Requirements are indicated within 3.1 and Table 3.1.5 3.1.3.1 A “use” for thermocouples is defined as one cycle of heating and cooling of the thermocouple (ce glossary). See Table 3.1.5 for maximum number of uses of a thermocouple. -39--40- oaks AIAG. Special Process: Heat Treat System Assessment Version 3, Issued 1072011 Tho catalyst er pook performance 3.1.3.2 Damaged expendable or non-expendable base metal SAT and TUS thermocouples shall not be reused. 3.1.3.3 For reuse of Type K and Type E test thermocouples, the depth of insertion shall be equal to, or greater than, the depth of insertion of any previous use.AIAG Tra catayst or posk peromance cal-9 ‘Special Process: Heat Treat System Assessment Version 3, lesued 10/2011 ‘Table 3.1.1 THERMOCOUPLE TYPE (1) Caen aa On eae scat Calibration and Replacement Requirements for Thermocouples Used for Control, Monitoring and Recording. NN) on UC oc erg REQUIRED Base Metal Types | 2 760°C (1400°F) | Calibrate before firstuse. | Primaryor | # 1.1°C (+ 2.0°F) (KNJE) Replace Annually (2,3,5) | Secondary _| or Standard. | #0.4% Base Metal Types | < 760°C (1400) | Calibrate before frstus®. | primary or | #1190 (#2.0°F) place Every Two Years or (KINW.E) | 23.5) Secondary | 0.4% 8 Standard. Primary or | #4.1°C (4 2.0°F) Noble Metal Types |. ragsc cx4gger) | Calibrate before first use. °C (1400°F) Secondary | or (RS) Rerlace Every Two Yeers | Snda | S04% 1, Non-Expendable 2. Thermocouples shall be replaced whenever needed, e.g. failed SAT, or damaged thermocouple; however, thermocouples shall be replaced minimally as stated above. wae Base metal thermocouples shall not be recalibrated, ‘Nobel metal thermocouples Type B, R, and S may be recalibrated in lieu of replacement. Does not apply to Load Sensing Thermocouples. See Tables 3.1.4 and 3.1.5 -Al-cate AIAG 2 Version 3 Issued 10/2011 Tho catalyst paok portance ‘Table 3.1.2 ~ Calibration and Replacement Requirements for Thermocouples Used for Primary and Secondary Standards See aa ast (oe a CMe COL OLN ai ita TC Coe MEN REQUIRED Primary ‘Types R and S Secondary | Beforefrstuse. | Reference. £06 (+ 1.08) Standard (1) Noble Met Standard Recalbrate each | Standard (3) | ot Calibration | thro (3) years £0.1% whichever isgrester ‘Secondary Types R and § Tost Before frstuse, | Primary 206°C (1.0) Standard (2) Noble Metal ‘Thermocouple | Recalbrateeach | Standard or Calibration” | two (2) years. £0.1% whichever — isgrester ‘Secondary Type 8 Tost Before fistuse, | Primary 206°C (1.0) Standard (2) Noble Metat ‘Thermocouple | Recalbrateeach | Standard or Calibration” | two (2) years. £0.25% whichever is _grester ‘Secondary Base Metal Test | Botoretrstuse. | Primary 211°C (£20) Standard (2) ‘Thermocouple | Replace each Standard oe Calbaton” | one (1) year period £ 0.4% whichover | minimum is greater Recaliration prohibited (4) 1, A primary standard thermocouple together with a primary standard instrument shall be used to calibrate secondary standard thermocouples. 2. Use is limited to the calibration of temperature uniformity, system accuracy, controlling, recording, monitoring, and load thermocouples, 3. A Type R or S noble metal thermocouple calibrated against a NIST (or equivalent) reference standard. No error permitted, 4, Base metal thermocouples shall not be recalibrated. 42cal-9 Special Process: Heat Treat System Assessment Version 3, Ieued 1072011 ‘Table 3.1.3 ~ Calibration and Replacement Requirements for Thermocouples Used for ‘Temperature Uniformity Survey (TUS) and System Accuracy Test (Sat) Breen Curent Cn LN iia cae TN oo org MuesvNe Gees) Types B, Rand S | Temperature Uniformity | Before fist use. Replace or | Primary or £140 20°F) oF Noble Metal suneys RRcalbrate every 2 years. | Secondary 204% Standard ‘Types 8, Rand S Before festuse. Replace or | Primary or £190 20) or Noble Metal SAT Probe Method | Recalbrato every 2years, | Secondary 204% Standard Types B, Rand | SAT ~ Comparative | Before fist use. Replace or | Primary or 219°C (220°) oF Noble Metal Methos Recalbrate por Table 3'.1 | Secondary 04% ‘Standard Base Metal Temperature Uniformity | Before first use. Replace per | Primary or £140 (220°) or Surveys. Table 3.1.5 (1) ‘Secondary 204% Standard ace Metal Before frst use. Replace per | Primary or 214°C (£20°F) oF SAT Probe Method | Tabie 3.15 (1) Secondary 04% Standard base Mi Primary oF = jase Metal SAT — Comparative | Before fist use, Replace per | COTO" £1:°C (£20°F) or Method Table 3.1.1 (1) poe 204% Base metal thermocouples shall not be recalibrated. -43-gout AIAG 2 Version 3, Ieued 10/2011 Tho catalyst for poak prtamance Table 3.1.4~ Calibration and Replacement Requirements for Thermocouple Used for Load Sensing aT saUereroll an OMT NONE WN) MMA) ani ia os I ERNE Yong sn REQUIRED Types B, Rand S| Before frst use. Replace or euneay or £1.4°C (£2.0°F) or Noble Metal Recalibrate every six (6) months, y £0.4% Standard. Before frat use. Replace par | Primary or Base Metal Table 3.1.5 Recalibration ‘Secondary ie eee prohibited. (1) Standard 1. Base metal thermocouples shall not be recalibrated. ‘Table 3.1.5 — Allowable Number of Uses for Thermocouples in Specific Appl tions Coane en ae eS ba peas Expendable Base Metal | Temperature Uniformity Surveys! | aso 1g00%F) 5 Expendable Base Meta | Temperature Uniformity Suveys | > sparc ago0r) 1 Expendable Base Metal | Control (1) all 1 Expendable Base Metal | Monitor/Record/Load Sensing (4) | > 650°C (1200°F) 1 Expendable Base Metal | Monitor/Record/Load Sensing (4) | < 650°C (1200°F) 30 Y able ‘Temperature Uniformity Surveys, Noncexpendable Base | SAT and Load Sensing + 980°C (1800°F) 180(2,3) etal Thermocouples (5) _— “Temperature Uniformiy SuNeyS, Norcexpendable Base | SAT and Load Sensing > 980°C (1800°F) 90 (2,3) M Thermocouples (8) 1. Includes Load Sensing Thermocouples used as a Control Thermocouple. When a non-expendable base meial thermocouple is used above 980°C (1800°F), the maximum total number of uses is 90 uses which shall include any previous or subsequent temperature readings taken with the subject thermocouple 3. Inthe absence of documentation ofthe number of uses for non-expendable base metal thermocouple used for TUS and SAT, then the thermocouples shall be replaced after 6 months, 4. Expendable base metal thermocouples for load sensing, are allowed more than one use if thermocouple shows no visual degradation. Documentation is required to show compliance 5. Non-expendable base metal thermocouples for load sensing, are allowed more than one use if thermocouple shows no visual degradation. Documentation is required to show compliance.AIAG a cals ‘Special Process: Heat Treat System Assessment The cata for paak pertamarco Version 3, Isued 10/2011 3.2 Instrumentation 3.2.1 General Instrumentation Requirements: Instrumentation shall be selected as appropriate for their intended use and shall meet or exceed the accuracy requirements indicated in Table 3.2.1 3.2.1.1 All instrumentation calibrations shall be traceable to the National Institute of Standards and Technology (NIST) or national or international standard. 3.2.1.2. External sources providing calibrations shall be accredited to ISOMEC17025 or other national equivalent. Internal sources providing calibrations shall do so in accordance with the intent of ISO/ECI7025 or other national equivalent. Records shall be kept of training and qualifications for internal personnel performing calibrations. 3.2.1.3 Calibration frequencies and accuracies are specified in the applicable Process Tables and in the Instrumentation Table 3.2.1. A grace period of 2 weeks is allowed for all calibrations. 3.2.1.4 The temperature for each control zone shall be recorded by a recording instrument, 32141 Recorder shall be operating during the entire time that product is in the furnace ‘and print intervals/sample rates shall not exceed five (5) minutes for analog recorders and two (2) minutes for digital recorders. Process record shall be legible, 3.2.2 Readability and Resolution: The following represent minimally acceptable requirements: 3.2.2.1 Test instruments shall be digital and have a minimum readability of 1.0°C or 1.0°F. 3.2.2.2 At least one controlling, monitoring, or recording instrument for each furnace or oven zone shall have a minimum readability of 1.0°C or 1.0°F for digital instruments or 2.0°C or 4.0°F for analog recorders, 3.2.23 Temperature resolution requirements for digital and/or analog furnace chart recorders shall comply with the following: ‘55°C maximum per centimeter of chart paper © 5°C maximum per chart line increment 250°F maximum per inch of chart paper 10°F maximum per chart line increment 3.2.3. Offsets: The use of offsets is generally discouraged, however when used, a documented procedure shall exist which at a minimum describes when their use is permitted, how to perform manual and electronic offets, how to document the basis for the offset (calibration, SAT or TUS), how to account for the offset when performing calibrations, SAT’s or TUS’s and how to reintroduce any intentional offsets, The procedure shall also indicate who has the authority to approve the use of offsets and how this 3.2.3.1 Offfet or bias applied to the instrumentation calibration shall not exceed 2.0°C or 4.0°F. -45--46- cal-9 Special Process: Heat Treat System Assessment Version 3, lssued 102011 3.24 Calibration: Calibration of control, monitoring, and recording instruments shall be performed to the manufacturer's instructions; however calibration may be performed as described in 3.2.4.1 3.24.1 For the calibration of control, monitoring or recording instruments on furnaces that are in operation and running at typical operating temperatures, a single point calibration is acceptable (parallel reading of thermocouple input). For furnaces with a load in process, the furnace temperature shall remain within processing tolerance. 3.2.4.2 For each channel or group of channels in use that can be altered or adjusted, a calibration shall be required. 3.2.4.3 Calibration Frequeney of the control, monitoring, and recording instruments shall be one of the two options listed below: 3243.1 Option 1: Quarterly (single-point or multi-point calibration; see Glossary for definitions) 3.2.43.2 Option 2: the frequency may be semi-annual provided that the SAT is performed ‘quarterly per Probe Method A (per 3.3.4.1) AND the multi-point calibration is employed for the instrument calibration 3.2.5 Calibration Records: Calibration status and results shall be reported as follows. 3.2.5.1 A calibration label shall be affixed to the instrumentation device, or in the case of panel mounted control, monitoring or recording instrumentation, on the device or as near as practical to the device(s) to indicate its (their) most recent successful calibration. The label(s) at a minimum shall include Date the calibration was performed. Due date of the next calibration, Technician who performed the calibration (initials are acceptable), Serial number of instrument 3.2.5.2 Instrumentation calibration results shall be documented. The instrument calibration report or certificate shall include the following information: * Furnace or unit identification number Make, model and serial number of instrument calibrated (not applicable to PLC controlling devices) Standard or test instrument used during calibration, Method of calibration, Ambient temperature and humidity Required accuracy. Initial and final values at each calibration point (if no adjustment is made then the final value will equal the initial value). Initial and corrected offset/bias values (if no adjustment is made then the corrected ffeet?hins value will canal the initial vale) Statement of acceptance Any limitations or restrictions of the calibration Date the calibration was performed. Due date of next calibration, Technician who performed the calibration.AIAG 2m cae sunt crane The cays er peak pefxmsnce Version 3, sued 10/2011 * Signature of the technician who performed the calibration. © Calibration company if not performed in-house. ‘+ Sign-off by responsible person in the heat treat organization. 3.2.6 Electronic Records: When using a system that creates electronic records the system shall create write-once, read-only electronic records that cannot be altered without detection, 41.3h we sjuowneu) ‘uowdinbo Busssoo0.8 wowoy wre upioooy} rewuarg wea youend pue uogesebujs 20(69jeue) | 40 Bwwowuony So} 849 BUUSeOU Of POI (aor) 007 e reauewon, “yong, we ‘suownssuy queues Sujssc001d ewoy) jo ameroduia 94, Suyosuos pus “Bupseoes“BuUnseou o1 PEIN (ov) oz? | e sfouns ‘yaioyun aurasaduia pue 80) hoeincoe a wownasuy worsXs sovewwoyed "vonesqyeo wuounssu plepueis 1801 Pd Burpiooas 10 "Bunauow, 4 pour) ‘Asepu0.9g 10 eile Buypioo91 0 "Baoyuous“Buyosquco pue sosuas eo) ‘siosues 86) Faxns Kjuuopun axreveduo} | —sojou6 s sonoyouy ‘10sv9s Js Fowsnooe woIeAS ‘swuounasu} | —“Buypeas 0 %C0'0 + prepueis 1821 prey Jo uonesqHe> Asowsonel aM | 30 (3.60) 9204 prepueis Aus zu ‘vepuases ‘ios prepueys Kepuores neyays pue fsouud pue stuousnasu S01 pe puepuers S100 piepueis ‘feepuo298 Jo uonexqye® KiojeoRe| O} POMUT] | 404107) 2.500% | RIEPUEIS SOLO. 9 Aiea pepuas prepueis eLONEN eouaiejan piepueis ‘vorexqie> puepuers Krewnd or pour | Na OSI20 1SINJO) ojennbo 10 1SIN, eo ‘bey0n 0007 souar9)9 Cerner) Ferri eery Tener te) SI Gener Prete A) oT ey aaivaernvo Err Prete PTET ES ]AIAG a cars Tho cata fr pssk partormance Version 3, Issued 10/2011 3.3 System Accuracy Test (SAT) 3.3.1 The SAT shall be made in accordance with 3.3, and the System Accuracy Test Table 3.3.1 requirements, 3.3.2. The SAT shall be performed using a test thermocouple conforming to the requirements of ‘Thermocouple Table 3.1.3 coupled with a test instrument meeting the requirements of Instrumentation ‘Table 3.2.1. 3.3.3 A new SAT shall be performed after any maintenance that could affect the SAT accuracy, e.g., the replacement of the lead wire, control thermocouple, or the replacement of the control instrument. 3.3.4 The SAT shall be performed while the furnace is operating at a typical operating temperature using either the Probe Method (Section 3.3.4.1 or Section 3.3.4.2) or the Comparative Method (Section 3.3.43). 3.3.4.1 Probe Method A: 33.411 Probe Method A is a check between the uncorrected reading of the control temperature system (control instrument, leadwire, and thermocouple) and the corrected reading of a test temperature system (test instrument and test thermocouple). See Illustration 3.4.1 3.34.12 ‘The tip (measuring junction) of the test thermocouple shall be no further than 50 mm (2 inches) from the tip (measuring junction) of the control thermocouple. Existing furnaces that have physical limitations preventing compliance to the 50 mm tip-to-tip distance shall be reviewed and approved by the assessor. 33.413 ‘The temperature indication of the control instrument connected to the control thermocouple shall be within +/- 5°C (or +/- 10°F) of the corrected temperature indication of the test thermocouple on a test instrument, After insertion of the test thermocouple, allow sufficient time to achieve equilibrium between the test thermocouple and the control thermocouple. 334.14 If the calculated SAT difference exceeds 5°C (10°F) the appropriate corrective action shall be taken before commencing with additional thermal processing. Control thermocouples failing to meet the requirements shall be replaced. A new SAT shall be conducted ‘on the replacement thermocouple. Actions taken shall be documented. Note that when using Probe Method A, any electronic offset value introduced to the control instrument for the purpose of centering a TUS result shall be icluded in the SAT difference calculations. 334.15 SAT frequency shall be quarterly. 49.ca AIAG Special Process: Heat Treat System Assessment Example of Probe Method "A" Over-Temp Thermocouple Controt ‘Thermocouple N, (A) Control instrument Over-Temp Protection Part or Raw Material Chart Recorder Test Furnace ‘Thermocouple Furnace Wall Work Zone (8) Test Instrument Lead Wire EXAMPLE OF ACCEPTABLE SYSTEM ACCURACY TEST (SAT) PROBE METHOD - A Con mae Devs “ Test as 2 F Drertisatgt ca aad a ay Test ere ' Gtk outta ee as (oo a ad aie (8}{C)*(0) ic) c ec) 900°C 901.5°C 5c +40.1°C 904.1°C (1652°F) (1655°F) ) (+0.2°F) (1654.2°F)AIAG 2m gata some tet The cata for pak partormance Version 3, Issued 10/2011 3.3.4.2 Probe Method B: 33.421 ‘The Probe Method B is a comparison between the uncorrected reading of the control temperature thermocouple indicated on a test instrument and the corrected reading of a ‘est temperature system (test instrument and test thermocouple). See Illustration 3.4.2 3.3.4.2.2 The tip (measuring junction) of the test thermocouple shall be no further than 50 mm (2 inches) from the tip (measuring junction) of the control thermocouple. Existing furnaces that have physical limitations preventing compliance to the 50 mm tip-to-tip distance shall be reviewed and approved by the assessor. 33423 After insertion of the test thermocouple sufficient time shall be allowed to achieve equilibrium between the test thermocouple and the control thermocouple under test. 33.424 ‘The uncorrected reading of the control thermocouple connected to a test instrument shall be recorded at the highest point in its temperature cycle, Immediately following, the test instrument shall be connected to the test thermocouple. The corrected reading of the test temperature system shall be recorded at the highest point in its temperature cycle. 3.34.25 If the calculated SAT difference between the uncorrected reading of the control temperature thermocouple indicated on the test instrument and the corrected reading of the test temperature system (test instrument and test thermocouple) exceeds #5°C (£10°F) the control temperature thermocouple shall be replaced and any other appropriate corrective actions shall be taken before commencing with additional thermal processing. All actions taken shall be documented, 3.3.4.2.6 SAT frequency shall be quarterlyfa AIAG a Special Process: Heat Treat System Assessment ‘Version 3, Issued 1072011 The cata fer paok perfomance Example of Probe Method "B" Over-Temp Thermocouple Controt Thermocouple N\, F Control Instrument Part or Raw Material Chart Recorder = Test Furnace Work Zone a ered ‘Thermocouple Furnace Wall K Instrument Lead Wire (A) Test Instrument (SAT) PROBE METHOD - B EXAMPLE OF ACCEPTABLE SYSTEM ACCURACY, mas e TEST Test j etic eisai iat eer ST Ao Pera A LCT ye Pore Xn cas Laat ari MEHCHOY aye) aS @) ra) ©) () 900°C 901.5°C °C 40.1°C 901.1°C (1652°F) (1655°F) O'F) (40.2°F) (1654.2°F) ‘est Instrument A and Test Instrument B are typically the same test instrument, [Note: Te “52AIAG 2 ao Special Process: Heat Treat System Assessment The cata for pak pertormancs Version 3, Issued 10/2011 3.3.4.3 Comparative Method: 3343.1 ‘The Comparative Method is a comparison between the uncorrected reading of the control temperature system (control instrument, leadwvire and thermocouple) and the uncorrected reading of any other permanently installed monitoring system (instrument, leadwire and thermocouple) in the same work zone, such as an over temperature control system, See Ilustration 3.4.3 33.4.3.2 The temperature difference (delta) between the control system (control instrument, leadwire and thermocouple) reading and the reading of any other permanently installed monitoring system, at the time of the most recent conforming instrument calibration test, shall be established (e.g., the control temperature system indicates 600°C and the over ‘temperature control system indicates 605°C; the delta between these two devices is +5°C).. 33.433 This established delta shall not differ by mote than +/-1°C (or +/-2°F) when checked at a typical operating temperature. It is strongly recommended that the comparative check be performed at or near the original comparison test temperature. See example below for calculation of delta. 33.434 If both devices have their respective thermocouples in the same protection tube they shall be of a different type (e.g., Type K with Type N, Type R with Type S). This is to prevent false readings due to similar degradation rate. 33.435 Corrective actions shall be taken to correct a failed SAT before commencing with additional thermal processing. A new delta shall be established after any maintenance that could affect the SAT accuracy, e.g., the replacement of the lead wire, thermocouple, control instrument, or calibration adjustment for either the control temperature device or temperature monitoring system. Actions taken shall be documented. 33.43.6 See Table 3.1.3, SAT Comparative Method for the resident thermocouple replacement schedule. 3343.7 SAT frequency shall be monthly.core AIAG Special Process: Heat Treat Systom Assessment | Version 3, issued 10/2011 To catalyst fey paak pertormance Example of Comparative Method Over-Tomp Thermocouple Controt Thermocouple N\, (A.D) Control instrument Over-Temp Protection, _— Part or Raw Material Chart Recorder \ Resident Furnace vermocouple Furnace Wall Work Zone (BE) Resident ™ et Thermocouple Monitor Note 1: Its recommended that the comparative check be performed at or near the initial temperature at the time of instrument calibration (See A & B temperature in example below). Note 2: Resident thermocouple and over-temp thermocouple may be the same thermocouple EXAMPLE OF ACCEPTABLE SYSTEM ACCURACY TEST (SAT) COMPARATIVE METHOD eu ort mee EcNis CRTC aan [3 Ms c itd F) orca © ro) Cc c +5°C 606°C 610! °C (12°F) (1121°F) (69°F) (1123°F) (1130°F) (-2°F) Deviation from the initial delta = B-D-C Conn Desig Coe SCs A oa 0 aS air DrncsIne art Stas Brera CHECK CO “4AIAG 2 cals Tho cata for paok perormance Version 3, ssued 10-2011 335 System Accuracy Test Records shall include the following: Identification of the thermocouple being tested. Identification of the test thermocouple Identification of the test instrument Date and time of day of the test Observed contro! instrument reading, Observed test instrument reading Test thermocouple and test instrument correction factors Corrected test instrument reading Calculated system accuracy test difference Indication of test acceptance or failure Identification of technician performing the test External calibration company if applicable Sign-off by responsible person in the heat treat organization“56 = AIAG a Varsion 3 ssued 1072011 To catalyst or peak portance TABLE 3.3.1 SYSTEM ACCURACY TEST REQUIREMENTS, RUG MAXIMUM Mane) Pag Su Pubes ta aad Giselle Prk) Probe Method | Typos B, Rand S uarterly £50°C (+ 10.0%) Noble Metal 3) Types K. N.J and E Base Motal Comparative Types B, Rand Monthy £10 2207) Method ‘Noble Metal 23) Types K, N,Jand E Base Mata! 1. Maximum value of the Calculated SAT difference (see 3.3.4.1.3 and 3.3.4.2). 2. Maximum deviation from initial delta (see 3.3.4.3.2) 3. Total offset/bias assigned to the correction of a SAT error shall not exceed 2.0°C (4.0°F). This permissible offset/bias is separate from offset/bias assignable to a Calibration error or TUS.AIAG 2m cars The cata for paak portance Version 3 issued 10/2011 3.4 Temperature Uniformity Surveys (TUS) 3.4.1 General TUS Requirements: Temperature uniformity characteristics, qualified work zones, and ‘operating temperature ranges of furnaces or ovens are validated by performing a TUS. ‘The TUS shall be performed in accordance with the appropriate Process Table and the requirements of this section. 3.4.1.1 Any furnace modification or repair that could alter the temperature uniformity characteristics of the furnace shall result in a temperature uniformity survey being performed prior to the furnace system being used for processing. See “Fumace Modifications” and “Furnace Repairs” in the Glossary for further guidance. 3.4.1.2 All furnace modifications or repairs shall be documented and include the determination made by the responsible authority within the organization as to whether these modifications or repairs could alter the temperature uniformity characteristies of the fumace 3.4.1.3 TUS Test Temperatures: If the operating temperature range of the qualified work zone is equal to or less than 170°C (305°F) then only one temperature within the operating temperature range is required to be tested. If the operating temperature range of the qualified work zone is greater than 170°C (305°F) then the minimum and maximum temperatures of the operating temperature range shall be tested. For aluminum heat treating, a tighter temperature range is given in Process Table C, C2.4. 3.4.1.4 TUS Furnace Parameters: When performing any temperature uniformity survey the furnace system parameters during the test shall replicate the furnace system parameters during normal production If atmospheres used during production present safety risks or could affect the accuracy of test thermocouples during a TUS an atmosphere of ait or inert gas may be used. ‘The TUS may be performed with an empty furnace. If the furnace is empty then the thermocouples shall be attached to a fixture to insure required test locations are securely held. If the TUS is performed with a loaded furnace the load shall replicate typical operations and the thermocouples shall be attached to or buried in the load. 3.4.1.5. Use of Heat Sinks: If the TUS is performed without a load the TUS test thermocouples may be attached to or inserted into heat sinks, however the heat sink shall represent the typical section size of the heat treated product. In addition, the heat sink shall possess similar heat transfer characteristics of the ‘material that is typically processed in the furnace under test. 3.4.1.6 Furnace Vacuum Level during TUS: The furnace vacuum shall be run at the lowest set point employed in normal production but need not be less than 1 micron Hg (1 x 107 Torr, or 1.3 x 107 millibar) when performing a TUS. 3.42 Continuous and Semi-Continuous Furnaces “ste“58 caus AIAG 2m Version 3, Issued 10/2011 The catalyst for peak pertxmance 3.4.2.1 ‘TUS Methods: Continuous and semi-continuous furnaces shall be surveyed so that the volume defined as the qualified work zone is tested. TUS test sensors shall be arranged either three dimensionally (Volumetric Method) or ina plane (Plane Method). 3.4.2.2 Number and Location of TUS Thermocouples 3.4.2.2.1 Volumetric Method: Shall be used with continuous pusher furnaces. See Table 3.4.1 for number of TUS thermocouples. See Figure 3.4.1 for the location of the TUS thermocouples. 3.4.2.2.2Plane Method: Shall be used for continuous furnaces where the product is continuously moving through the furnace, e.g., belt furnaces. See Table 3.4.2 for number of thermocouples. Refer to table 3.4.2 for the location of the TUS thermocouples 3.4.3. TUS Data Collection: 3.4.3.1. TUS test thermocouples shall be traversed through the furnace at a traverse speed typically used in production and representing all test locations as required in Table 3.4.1 and Figure 3.4.1 or Table 3.4.2 as appropriate 3.4.3.2 Data collection shall begin when the TUS test thermocouples are londed into the furnace. All temperature data generated by the TUS test thermocouples shall be recorded automatically at least every thirty seconds. The process record for furnace zone temperature shall be compared to the TUS data ‘to ensure compliance to TUS requirements. Manual data collection is not allowed. TUS data collected shall clearly show the soak period achieved so that the responsible Quality Assurance ‘organization can determine compliance with intemal process specifications defining suitable soak time. 3.4.4 Furnaces Other Than Continuous or Semi-Continuous 3.4.4.1 Number of TUS Thermocouples: The required number of TUS thermocouples shall be in accordance with the TUS Test Thermocouple Table 3.4.1. 3.4.4.2 Location of TUS Thermocouples: See Figure 3.4.1 for the typical location of thermocouples in rectangular and cylindrical shaped furnaces. For furnace work zone volumes greater than 8.5m* (300ft’), the thermocouple locations shall be similar to the example in Figure 3.4.1 and the additional thermocouples shall be located to best represent the qualified work zone. 3.4.4.3 TUS Data Collection: Data collection shall begin when the TUS thermocouples are loaded into the furnace. All temperature data generated by the TUS thermocouples and recorded on the process record for furnace zone temperature shall be recorded automatically at a frequency of at least one set of readings ‘every two minutes for the duration of the survey. Manual data collection is not allowed. ‘The process record for furnace zone temperature shall be compared to the TUS data to ensure compliance to TTS reanirements 3.4.4.3.1When the furnace temperature control achieves set point temperature, displaying a normal control cycling around set point, and the TUS test thermocouples have stabilized, then the TUS data collection shall continue for an additional thirty minutes minimum.AIAG 2 cals ‘Special Process: Heat Treat System Assessment The cata for pask partormance Version 3 Issued 10/2011 3.4.5. Alternative TUS Testing Methods: Design characteristics of certain fumaces may prevent the traversing or insertion of TUS test thermocouples through or into the furnace work zone(s).. In such instances it is incumbent upon the Heat Treater to develop acceptable alternative methods to provide objective evidence that temperature uniformity characteristics of the thermal processing equipment meet the requirements of the applicable Process Tables and satisfy the intent of this document. The alternative approach taken shall be reviewed and approved by the customer. 3.4.5.1 Property Surveys: In the event an acceptable altemative TUS testing method cannot be developed employing traversing or insertion of TUS test thermocouples through or into the furnace work zone(S), property surveys shall be accepted as objective evidence of thermal processing capabilities, Initial property surveys of the selected product shall analyze those characteristics that are sensitive to variations in process temperatures and shall establish baseline data against which monthly product property trends shall be performed. If possible the selected product is processed frequently. The normal process size range shall be represented in the selected product. When a two-step process is under review, the second step can be run on the samples independent from the remainder of the lot. Ifthe furnace qualified operating temperature range is equal to or less than 170°C (305°F), the highest and lowest operating temperatures shall be represented by the product property survey. Ifthe furnace qualified operating temperature range is greater than 170°C (305°F), the product property surveys shall include an intermediate temperature in addition to the highest and lowest operating temperatures. At least five product property surveys shall be performed at each survey temperature. Samples for product property surveys shall be taken from the extremes and center of the load. Monthly property survey trends shall include selected characteristics of heat-treated product analyzed by fan appropriate statistical technique. Trends shall be examined monthly with defined control limits. Processing will be halted if any property trend exhibits a shift beyond assigned control limits until the cause of the shift is corrected. 3.4.6 Permissible TUS Test Thermocouple Fi failure rate is defined below: lures: The permissible TUS test thermocouple ‘When using 3 to 9 thermocouples 0 failures are permitted ‘When using 10 to 16 thermocouples 1 failure is perm ‘When using greater than 16 thermocouples | Less than or equal to 10% failures ‘A temporary condition such as a short or loose connection where normal temperature readout is restored shall not be considered a failed TUS test thermocouple. No comer position failures of a TUS test ‘thermocouple are allowed. 3.4.7. TUS Pass/Fail Requirement 3.4.7.1 A temperature uniformity survey shall be acceptable if all previous requirements are met including the following: -59-606 caus AIAG Version 3, Issued 10/2011 Tho ctayt for poak perfomance © All readings of all TUS thermocouples and control thermocouples are within the respective temperature tolerance requirements shown in the applicable Process Table during the defined soak period and the upper temperature tolerance was not exceeded at any time. + The time required achieving recovery, stabilization or recurrent temperature pattem did not exceed the time limit specified in any applicable process specifications. TUS is run for the minimum required time. ‘+ The organization’s internal process specification defining suitable soak time was met. Internal process specification shall define suitable soak time at temperature requirements. 3.4.7.2 Reaction to TUS Failures: If the temperature uniformity tolerance is not within the established limits in the applicable Process Table, the cause of the deviation shall be determined and documented. The equipment shall not be used for additional processing until the cause has been corrected and the TUS has been performed successfully. 34721 If the correction takes the form of adjusting (offsetting) the control instrument, and if the Qualified Operating Temperature Range does not exceed 170°C (305°R) a resurvey is not required, but the adjustment shall not exceed the limits of 2°C or 4°F. If the Qualified Operating Temperature Range exceeds 170°C (305°F) then the minimum and maximum temperatures of the operating temperature range shall be resurveyed. 3.4.8 TUS Instrumentation: TUS’s shall be performed using independent test instrumentation meeting the requirements of Table 3.2.1 — Instrument Calibration Requirements and independent test thermocouples meeting the requirements of Table 3.1.3 ~ Thermocouples. ‘Compensation for known deviations in the test instrumentation shall be made by electronic or ‘mathematical corrections, 3.4.9 TUS Report: The items listed below shall be included in the temperature uniformity survey report: Fumace identification name or number. Method of TUS. Survey test temperature(s) TUS thermocouple quantity and location identification including a detailed diagram in three dimensional space, or detailed description or photograph(s) of any load, rack or set-up. ‘* TUS thermocouple calibration report to include correction factors ‘© Survey test instrument calibration report to include calibration data and correction factors for each adjustable channel or input. ‘* Corrected readings of all TUS thermocouples at each survey temperature. Readings shall be identified as comected or uncorrected. Any limitations or restrictions of the TUS. ‘Testing company identification (if not performed in-house) ‘Name & Signature of the technician performing the TUS. Survey start/stop time and start / stop date. ‘The data collection period or soak period as applicable shall be identified. Survey test instrument identification number.AIAG 2m gars Special Process: Heat Treat System Assessment The cata for peak pertormance ‘Version 3, Issued 10/2011 Control instrument tuning parameters, e.g., PID values Documentation of any furnace survey thermocouple catastrophic failures. Time and temperature profile data for all TUS thermocouples and control thermocouples for all zones tested. Control thermocouple data shall be generated by the associated process recorder or process data acquisition system. Indications of test pass or test fail status. Summary of final plus and minus readings at each test temperature. Sign-off by responsible person in the heat treat organization,-62- cal-9 Special Process: Heat Treat System Assessment Version 3, Issued 102011 Table 3.4.1 - TUS Test Thermocouple (VOLUMETRIC METHOD) AIAG Tho catalyst for poak performance Workspace Volume <0.1 m? (3ft*) 0.1 t0 8.5m? (3ft° to 3008) Number of Thermocouples 5 9 Note 1. For fumace volumes greater than 8.5 m’ (300M), add at a minimum one thermocouple for each additional 3 m’ (105 ft’). For example, for a 17.50 m? (620 ft) furnace, 12 thermocouples shall be used at a minimum. [Note 2, Total offset assignable to a Calibration or SAT error. ias assigned to the correction ofa skewed TUS shall not exceed 2.0°C (4.0°F). This permissible ofiset/bias is separate from offset/bias ORepresents thermocouple locations Figure 1.4.1 - TUS Test Thermocouple LocationsAIAG cals The eatayst for pack petrmance Version 3, ssued 10/2011 Table 3.4.2 - Number and Location of the TUS Thermocouples (PLANE METHOD) CIEE ‘£300 mm (1 ft.) > 300 mm (1 ft.) Qualified work zone width see Note 1 see Note 2 <0.75 m (2.5 ft) 3 5 3 0.75 mto 1.5 m (2.5 ft-5 ft) 3 7 15mto24m(5ft-6f) 3 8 ‘Add one thermocouple > 24m (8 ft) for each 0.6 m (2 ft.) of 8 additional width Note 1 Two TUS thermocouple locations shall be within 50 mm (2 inches) of the ‘work zone comers. One TUS thermocouple location shall be at the center. Additional TUS thermocouples shall be uniformly distributed throughout a plane perpendicular to the conveyance direction. ‘Note 2: Four TUS thermocouple locations shall be within 50 mm (2 inches) of the ‘work zone comers and the remainder shall be at the center and symmetrically distributed about the center of a plane perpendicular to the conveyance direction. -63-cae AIAG 2m Version 3 Issued 10/2011 The catayt for peak peroarce Instructions for completing the Job Audit The organization is to complete « minimum of one heat treat part job audit during each assessment. This should be done preferably on a part identified for one of the customers requiring compliance to this document. More part job audits may be done if time permits. Preferably, safety or critical parts should be audited. This may not be easily determined with fasteners, especially if the fastener manufacturer does not identify the end customer (auto manufacturer, tier one, ete.), It is recommended that the job audit be performed at the end of the heat treat system assessment. The job audit is not the only or main focus of the HTSA. The other three sections on Management Responsibility and Quality Planning, Floor and Material Handling Responsibility, and Equipment are equally ifnot even more important, The job audit of one part, one heat process, and one furnace is not sufficient to use as a basis to complete the other sections of the complete HTSA. The job audit is a compliance type audit/review of a specific part and its related paperwork and processing, including heat treat equipment and processing records for that job from the beginning re of a part through processing in the heat treat operation and inspection to packaging. Parts shall be taken from the shipping area at the dock or the end of the heat treat operation. If an automotive manufacturer's part is not available or identifiable, then parts from other customers requiring compliance with this document shall be used for the assessment. ‘The part or lot checked shall represent a major heat treat operation such as quench and tempering, carburizing and tempering, induction hardening for steel, solution treating and aging of aluminum, etc. In subsequent heat treat system assessments, different parts and heat treat processes shall be checked. The specific heat treat processing parameters (applies to 4.7 in the Job Audit) that are required in the job audit shall be added to the job audit form. This can be done by reviewing the customer specification(s), the Control Plan, the FMEA, and the floor work/job order. Each processing step shall be reviewed for proper produetion records/compliance’inspection. These steps can be compared to those in the Heat Treat System Assessment for the actual job/heat treat process being reviewed for compliance. The heat treat and furnace records for the actual tine frame/shift etc. that the job was processed shall also be checked. The actual furnace equipment and instrumentation certification shall be verified as being in compliance to the appropriate equipment requirements in the equipment section. For specific heat treat parameters that are proprietary (applies to 4.7 in the Job Audit), the heat treat supplier may enter the controlling document number, e.g., control plan or process sheet, on the Job Audit, ‘The parameters shall be available to the auditor for review but proprietary information is not required to be documented in the Job Audit.cal-9 Special Process: Heat Treat System Assessment Version 3, Isued 10/2011 oz & a o “ oe aso oye ronan pouen % & ad ve te st ss e x ae Ft | pegers hy seunyad 90 med a ruoe vanes towed Ser a fouee Novareenoaw| ty ea WI) = EO) |yogg | _ wewernbon | RvmOCOWSIE| ——vopeno pny cr a pesos] coepuogrrey’ [eotmununeea event] mum mucins | BameS mmaoieerer [were Section 4: Job Audit Form The catayst fr pak perrmance AIAG» upny gor - y uoRDeS 65G2 Tho eatast er peok partormance Special Process: Heat Treat System Assessment Version 3 Issued 10/2011 cal-9 SE Tapa a en ay oH Lamune aso =o] ao a FgueNd 10 Fovenbeu 301] zi oT Tramaineeal TS aaa coz | wooate soporte o Wore maa po ea me | sonezemon ve (Ge senu er oun 90) voroyoee i swodovsemosoan| zy | wns | (e209p03 002080) | son eee wwouounbou | yuotseno veLH ana - bons esvetea) voupuca enoy | MARIBAIOG 2HRPR | muouriosoucien |” Pare fenoipeycor | #tensero -66-cal-9 Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 Tho cata for pak portormarce AIAG» 61 RTA 10 spolao aeucosdceu jo soy srownnioo pu syed og ry] 01 te fa pouty voueoyuiea ou. seha)| Sth erases sz ' wy eur. uy by ve zt ow. We ez ee SL ey vin | (@2uep3 ompoIa0) Cac ie vosson vsus ov) meets 20020) |vepmananang oenp mn vi woaseno yony ger se vonssnp [3,284] 2 1 p10 (dus) aorTho catalyst for poak perfomance ‘Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 cal-9 3z Taw] OCF ez Ayedord ssouewoo ou 9194 _| Be ez, Lpomvept fuedoxd sued ow som] evr _| Suaweunbey Burdaius| Cleats Jo KBSy Fe para ‘sued oyu J) sed pou oz caw opedeoedeuoday| ery _ | Pau ez swoweinte: Oubesed ery] uy _| suaueninbag Bulbeped| TaaweAnba wns | (eovepna eneo) | cpaurencen sos ‘woweunboy | uogseno VSIH an uogeor lwes/s8ed] uoapuea reney | YRsRNRS SNe | euros 0 1oucrsng |” poe an feeesro 10 19610 (dus) aor 68AIAG 2m cals Special Process: Heat Treat System Assessment The ctabat or pook perermanco ‘Version 3. Issued 10/2011 APPENDIX A- PROCESS TABLES PROCESS TABLE A: CARBURIZING / CARBON CORRECTION / NEUTRAL HARDENING / AUSTEMPERING / MARTEMPERING / TEMPERING / PRECIPITATION HARDENING - AGING... PROCESS TABLE B: NITRIDING (GAS) AND FERRITIC-NITROBARBURIZING (GAS OR SALT) . PROCESS TABLE C: ALUMINUM HEAT TREATMENT PROCESS TABLE D: INDUCTION HEAT TREATING .. PROCESS TABLE E: ANNEALING / NORMALIZING / STRESS-RELIEVING.. PROCESS TABLE F: LOW PRESSURE CARBURIZING ... PROCESS TABLE G: SINTER HARDENING. PROCESS TABLE H: ION NITRIDING GLOSSARY.. 69.cal-9 Special Process: Heat Treat System Assessment Version 3, lsved 10/2011 PROCESS TABLE A: CARBURIZING / CARBON CORRECTION / NEUTRAL HARDENING / AUSTEMPERING / MARTEMPERING / TEMPERING / PRECIPITATION HARDENING - AGING AIAG» Tho cata or peak performance [average Dow ar sbordatnt USOT =peTE ToT [re costomer may hav dations equement, Inspection twsthg, ete equenles ete, When peroming he job tlt the suo shal vert at eae [oafrmingts he cotome' auerents: [contnuous face requencle pela (wek oda] or 8 plied whichever e more eget rman Exp noncomplanes in eles KTSAGueston#) ago rae Ta a “PROCESS AND TEST EQUIPVENT REQUIREMENTS RT era NS 37 fanaa ee TTS [118 [atm ears ad gpa Bo WEE ES STORET ‘1a | 22 [Furaowsgh so sabe wets corey and calioneg aml te rma ras | 32 Paynes, Ss saicionnin an cor Hconbaian jan ih Soa aya] TOYS TET BTS mala Lapras emerson eee onan fA pM EN aaa | ae Pirates et anne (oreo Sa Ge Ts ETSI TY TN, BT TT TY ST PS stone GO serdar Saar oe proved dad TACTO| 2.18 es testi hare sab rtd pre Cer ecu aris] 32 RRSSESS DPI cher ant ashe Sai TS ATT Das EIT TrROETEY rSRTHORTRE REY] 32 morse a Ran BSE TAT TSE RET FE ST SB TT TTT TOIT Baa aE a Sr RT ATR TS Ra Fs ORTRT WOETSTO TTT REE] 3d aS ST a a TO RT SOT lemoerin unos rancor harenng anaes alle oS (or 4 5°) Tenperow ener lane ernie Jenscorahl bo 10% fra 35 cron pert or austere porears ali ae an TES TEs os BT frtnouseomarg pert, Fenster alo ar cokes Segal eon sas ese howe. ror Coninuous Furnaces, the equement apis othe Gusifled Wok Zon, TIE 35 errcacieromata an ery ar pcos ig pacuan tal be corand who SCTE TO APT fe romeor ecg pyomais Funace inp sal te Seed wn animes sng at [emcees eet),AIAG» ‘Tho cata for paak portance Special Proces: cal-9 .: Heat Treat System Assessment Version 3, Issued 10/2011 PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Restoration / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging nme yt cn. ne ee pe ty coenrtnar tentang tae h no n a Seemann Sse Rar SR cae aa PROCESS MONITOR FREQUENCES: = = ‘Atmosphere Generation | OK/NOK IMA = |_ “om Fae era aera porta bearer Esser besaseneree 3] — baa TR ed bene 3 TST eae eT iar” baton aneane bearer Piece aie ny =} i ERT =r br} it} oar a =e a ee Tecals G Sera rors tnt ot ts ascot AIAG 2 Version 3, Isued 10/2011 The catast or paak perfomance PROCESS TABLE A -Carburizing ! Carboniiriding / Carbon Restoration / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging [ectmer mayan dion wien 9. operon eng segues, he perm eb ah, eur shal vey alt meesnser rot (work neo pets hbase mor rauant 1K Des hat conply to faut Ecpan nancompanse in Rested HTSAQueston#) Saaqurmen no aposable ‘on aaReWTER Canons ape a Tea TST 2) [pepe sage er a 355] a a roar SS ET PAR ftsreaitoret Ras Bar Conia [ORTRORTAR] [oPROGESSFINAL fr ea pao oe a Sa a To | RUERERART ANS SOLUTION TEST ——| ae Conan r ORTH 71] 7 — ee sa ae Same i eee r 7" ae ee aa aa ae ra aE aa 757] 713 — Brine or Cause Gene eal nee 3a Gone eee a ~ eerie [ator fair Si Ritter eqearene cea — pT aI TSE] 7s — Fost Bente Soi OF Eine a a Geel al PetarAIAG The cata fr peak perfomance cal-9 Special Process: Heat Treat System Assessment Version 3. Issued 10/2011 PROCESS TABLE B: NITRIDING (GAS) AND FERRITIC- NITROBARBURIZING (GAS OR SALT) Rr TT cS a RTE TT I cetne mayhem ipston ng, aqanc ete, peoming theo ht sa yt nt [cro tothe cteon’ recuse lnm eae gun ae por ako ot pd wihee mae eet (ac: notsonpy tr astnent Exp encoeetonee i ebtedHTSACuston#) 7 ‘ROGERS Av VST EQUPNENTREGURNENTE peer | tae a EO AT AAT Pa 3 [eamesae booaiarco is I TT TOT A TE TTA TR TT TTT AT HT 57] ST TE Sr = PimWeTRT [SETRSRT ro SRST CATA TP a a SEN TT | 8 a TS CIS SE ROTT = ETS TE TO ETT ST SRST TTS PSSST renee went ree ates CUS °5 Fmnetnveme sb osnsw cen negate ween eo) “TB“14 sore AIAG Special Process: Heat TretSystom Assessment | Version 3, Isued 10/2011 Tho catalyst or oo0k partomancea ‘PROCESS TABLE B -Nitriding (Gas) and Ferntic-Nitrocarburizing (Gas or Salt) [incom ma ne ton eens, pein sg eb anu, he pgs te mor ha eth es [mgt coer fester ee Se oars ol foscor 2Rous). Alem a ee sp a ates an Essieors" fSamatons ef ercri eo eT a ber See Se et — aaAIAG 2 oats ‘The cata for posk partormance Version 3 Isued 10/2011 PROCESS TABLE 6 - Nitrding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt) a aaa nm Ta ‘Generators | SaitBath [OKT NOKINA| La memes = = = Be a TOT ar aT aa Ly — as “Oemerators | Sait Bath [OK / WOK’ Mal a | eee TT 7 —— ae — See aa =e E Be) on PRR Re ee toa 7 aaa ae Sarah TEED a — aie = = = ro = TacaQl-9 Special Process: Heat Treat System Assessment Version 3, Isued 1072011 PROCESS TABLE C: ALUMINUM HEAT TREATMENT AIAG Tho cata or peskpertomanca [ARENT Gea IE OTS TORT SE aT ve acon euros, eg Inspection etn, renter aqunces, et. When promi te job ua he uate sl ety ed eter = [Serene case reauemers |contnowsfomace equ ar pe et wer rr spend whiter are eget lox comptes torent I Snes nt compo egret Exp noncarpance in Rea HSA Quezon #) fies Rocarement nt spicade ra ar GSTS lourtons 7 PROCESS AND TEST EOUIRIENT REGURNENTS ORT NORTIA aT | 1 a a gr TT ar SS TS FATT TE a a TR TT TT TTT a [ie sstu shears BO wariea since cromroey eo CAE a tan aT ae ST A a TAT SS 52 Re a RS ee ae A a TTT OT aa = SRR TES |S a ER RTS TR RT TH OST HTH SST VT TS TST EE | Sa a AT SRT TOS TOOT OE GTA TIS TS TTT TENT |Teneactre Unto oo andar teas cal eo 80 Tenersreuntxmtyoarce er aresig hares lions 2 fooremstom areas Pen aye torte ended Tie lonsnte shal ete coer |ror conus Face. is equranent ppt he Guid Work 28 © [3b ani Rar Peaster al bocot TART OO TEATS fase crruncneooargbromce. Fiore per le Soe wacker soon ate eet fers ss ra tere lrorconinuou Furnaces hs requaent apples othe Gs Work ane oF TREE SAT ROR SSS STAT AAT OTT AIS SE OT Fennimore promos. runs enpertue aloe otledwh okies srr ale bree Forcomnnuous Fumacs, his eurament apps othe Qin or ne [Ea] 32 — lea ae ae aT a Reps SEI HOSE STOTT TEAIAG» cals Special Process: Heat Treat System Assessment Tro cata for pak pertormance ‘Version 3, Issued 10/2011 PROCESS TABLE ¢ -Aluminum Heat Treating Fa eRe HT Sew ETS SON PRE fr csc yr aeons pin tn er enh, WW pig 8 ha tye fonts ana tguacie a peri (nk rd oa pci cheer ect comps o eget one cong eqn Exp oncom need NTA Qeron#) Ta ‘Sa TE stper inten fae sft aaah fpr inant sen [eSeany te grat = — ace CRE BerwOKTER—| 8 [leressias fiorotwery2tavser |winacrat set 2 bere "con" [etnias retire sm oem epee [ae coe Ute fretrcrensomes [ete carc 7 Persngpeatnuahonm ono ata Ta EGET Cao RISES PETE a oT GPE 212 scenes ra alent te eae peer a orTWoKTIE = TT ‘ORT WORTIO arte Sen * Eee feos eT 7 ae ST Sa 1 Peeeearoa —— = footed ote shoe set nee 1cal-9 Special Process: Heat Treat System Assessment Version 3, issued 10/2011 PROCESS TABLE D: INDUCTION HEAT TREATING AIAG Tho catalyst for peak perfomance RST aT ER Ta RE a "cataract fea eos 9. Rept sr. setae, When pan eo se seh hy ak [nox Gove net conto eadtemet (Eps noncorpancs Rind KTA Gon) Regaremst to Fat TD EF oa 7 ‘ROCESS AND TEST SOUP RESORTS ORTHO Te A SS Se ral RE STA ae eI TRO oF 2S Sa RT a AT ors 2 SS RTE AN SR aT A ATS TT BET a FREE a prensa ais ead alvosghee! Seon EGET S appaSE TENTS OE oo ROSES MER TORNG REGUS Tre [Apso rio a eae ca SR Sahn a ro, aa RH [fom chen pes parma st eta rit csr ep ce a FETT TTT STITT SAE aa a TAT ART wr) a pena TNT RT oT ST TTT CSE TS ATT — OTHER . eae a a 7 aan Sees eg a BE] aE a OT SS Fite em eto monraon cuesAIAG» ‘Tho cata for poak prtormanco cal-9 Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 PROCESS TABLE D - Induction Heat Treating [Aira ro aw RAGE stor SPRE RUA |rnecustome may hve actions rqirarant, npn tng, rater equnle, ec nen petri the ob th aur sal vey eat |restare conning the urtomers equremens loc comps to ragirarant Soest conph to regiment (span noncompliance ia Relates HTSA Question #) IRs Regret net splabe TT | Rata TSA Sa Ss ueston ae ES rarest a SRT ee ST fotown mats ci) ° oF FE ST RT {aR SET RATA STORY TIT OT 2 mr pt er eset ar sone oF 5ST FT SITS RAGE TST GTR one aR wT TFET TT 21 [mapnaione few son ot atow sx |! ut ea arn bol chorue, one er san sy fiscovouratveulsacwneeshatbe [uno maken sc) [ Te rg One RE ST RG Cp STF ATS au [eect [SR Rana nar ATE RRR TTT LS GE RSET TS GE HH SAITO etna sh next ston aurene) Te 7S iste Sal [eomsue tea ET a pene -19-cal-9 proces Heat Tat System Asersen AIAG 2» Special 2 Version 3 Isued 10/2011 The etayst for poak pertomance PROCESS TABLE E: ANNEALING / NORMALIZING / STRESS- RELIEVING i ecarenen en ae re TRS TST RST TOT [= cstonar my tae ations unt. nspcton stg, rete gunn ete. When promi the ob sf the Butoh vey heat raters Jfestcming tector egies, feortinsousturace neues ae prt won oe ora pu wits is moe eghet fart o meu Iho: Goesnt cont to raurerent xn roncorpsice nied HT Question #) fins nesurementacapptcobe r r I emer] a PS ‘aeston po HRS PENT RESORTS JORTHORTIA] [Et patna an an are NS) RT TTPO STO TEA Pe a RT SR SRT STALE SA STS RT PETS | a para ag TET GaN aT TTT Co a frases Soive ciuctezevaaly tsar. Iver appomieuten oxi ncavangcotoe Ses avons PES] a — Re SS TET SA EST RAT BT ROT TTS TST i [EO] Ba rae aS TS SST SEE EO a TT fro pavtcatatonrer stores). THe spleate whens nconting catnteang ence TE] EE a ap TSE TT TS RT BPI RON TRIES S TT FST “TT] 37 — ean opey zed cec tronics ad waa ear) Halon ae a oe WA FATT WITT ae sy Gt andacoure ears aa ee Pe ROWER [SRT RORTRR EEF] 3 ir a a as al SOT TTT EE] 3 a SSS STN HT A TT EIS | 32 Ra aE SI TTT TTT RET TT TE HB OTT OR TT SATS Jems untrny earn eres peat itty empaaee ab 980 fori. 2 Temper way wore ergetegturasn eal TS] 35 Free toner asetang soreness be coro wtn 10 iy 67) oT REDS a TTD [sabusvs meri proms, Frac tweperare salto comolod wn sos tne es ewe leucine ees foreAIAG 2m cals Special Process: Heat Treat System Assessment Te cataytr poak poromance Version 3, Issued 10/2011 PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving [RRR ST IGS SBS SC SSE CTT [rte my hn sate osname 5K Compe torgurent 3K Doesnt conpy to ret Exp onconpiane hela HTEA Question #) Ee furace eget peri Woo or a pata whichever mre agent "peasant apps L a ees EA CaS Ta iz ‘Bech Fumace ‘Genesio | EET] — ta — flees now rere GFF TTT STE FORO Fisec"As [nds rece Kl oe | peat a Semiybe | aa Ea 0S RLS SST SST CT zie mone frcena, ns riogen mara sen ray oe’ o= ar [sun mented ans aie, Ssgnoh ee rae frstme acter sm eters fants) fer festeumncr ets ty fecuemere “Tt scent-82- gana AIAG 2a Version 3, Issued 10/2011 The catalyst for paak prfermsnca PROCESS TABLE E - Annealing / Normalizing Stress-Relieving a | usorar may have ational requments,. npectn ting, retrtaquanls, te, han prong th Jb AE. tb aos wt ea etre foreiagio te cstonars eau lontruces ace quences repre Wor oh) or an speed, whichever le mor faqut lx. comptes oregon |x - Goes not compl torequanen(xpan poncomptinc Related WBA Queston#) J crm tapped I I [nafs Sa oo ROSETTES | Bah | Ca [SRTRORTIA [eta sae =r] a — Ta ens 215 teat frstexnnin Weer aoe 40 pccstr is 37] 7 sr es — sae aa 25 _fpesten 5] eoaoron esr Sama ORTHORTRR| ean Famce TET] 73 — ease Sona a Fasemacraraas— pair a fers iene ert)AIAG The cata for peak performance PROCESS TABLE F: LOW PRESSURE CARBURIZING cal-9 Special Process: Heat Treat System Assessment Version 3 see 10/2011 i ean ar Bi a RE SS PEO ETS Cee age a are anne nem —— Se eanennenne nine Ser: = =a — aren — : _ — fa 7 — | SRTRORTRR | Samana“84. cal-9 ‘Special Process: Heat Treat System Assessment Version 3, Issued 1072011 PROCESS TABLE F - Low Prossure Carburizing ERE BWR I a8 TATE ST PTE TS caiomer ty have tonal eqns, npn testing, ale Hogs. When ptormig heb se he or hal ety eae Conforming the casa ques 3K comple requrement Koes ot amp eurement xp nencomplnceia Rented HTGA Question #) hagas opti [= TT cra eer = a ar if Tears WF OPO, I ae ay ae RT my ena | Era re a =a ieee cr ra oo ver] 0 — a ial pts shor (ORTOTTTOTETG BOER A AIAG» Tho catalyst for peak performanceThe cata fr peak porormance cal-9 PROCESS TABLE G: SINTER HARDENING ‘Special Process: Heat Treat System Assessment Version 3, Issued 10/2011 ETAT TE RT TT [cm raat srr. en etn et acy lonnoefenns queer en odor ape ceva ire etme eens cunt a | aT ER SS we ‘ROGERS BS TERT OUR EIRENE ———P-serasrma-] ar] Se RTS A TT ama ar] a Sa TITY ST TAS sr} ST RTT TS TTS TR TS EE BAT oo STOTT] tt ES TE TT CER TTT RST CITT Be ETL TOT sce tty an rade se 1 4 5} Tepe tomy estan mae attest et eae ae care eaaocasr ues a ceca Conse Fracs atone ops tuned Wee Zo -85-gas AIAG a Version 3, Isued 1072011 The cata or peak parlermance ‘PROCESS TABLE G--Sinter Hardening te. Ye peering eb ub nt a wy et een Jnana pro Won lid cbr mre age cx: Boes wt con epomnn (tan toncomptanceWaktes TSA Guten fitshetcnent mc rae [Roasenren Sao Tape we PRocess NONTORFREGUENERS tool Se ‘armani oan | OWA TE Ren ena areas liars) —[ainct tot eras — [aa ns Ta ST fetes nel ae Femmsy ose fas eee cemen ence Feat erence eemrentercrrarer lsum sper epee mec eae a ete =o : ee [acorn fesseAIAG» Speci! Process: Hat Tet System The cata fer peak paar PROCESS TABLE G - Sintr Hardening TTT STR CT TT TE age matting tea Yani Be Be sh tye loatnacuin gins pct wrk erat spect whlchee hwo ue [cmt Epa ncngnes ns) a SS Sao aa TS ners tuacntatne pate = |88 cal-9 Spec Process Heat Tet System Assessment AIAG 2» Version 3, Issued 10/2011 The cata! o0ak perfomance PROCESS TABLE H: ION NITRIDING PT TTT [mcr natn ctan gence eng he he ae a why cna be Ina tn ornwnigga ey hYAhB ad niga lx csmeo farmer haope ad HEA en) Ieteoprenesaeae 2) SE ST RT SS ST STS TTT STA aa] ar TSAI STR TT RT TTT [se FY area SRT 1a] ee je co SOUL YESTS “psy |r| | aa TT re na _ecume TET RIE — TTI] fe ae Lt aAIAG cae Tre catator peak perermance Version 3, issued 1012011 GLOSSARY Glossary of Terms In the context of this document, the following definitions shall apply: Accuracy: ‘The closeness of agreement between a measured quantity value and a true quantity value. Adjustment: Set of operations carried out on a measuring system so that it provides prescribed indications corresponding to given values of a quantity to be measured. AIAG: Automotive Industry Action Group. ‘As Found Data: Calibration data collected prior to adjusting (see Pre Adjustment Calibration). ‘As Left Data: Calibration data collected after any required adjustment however, these values may be the same as the As Found Data if no adjustments were made/required (see Post Adjustment Calibration). AS American Society for Testing and Materials. Base Metal Thermocouple: Thermocouple composed primarily of base metals and their alloys. Examples of more common base metal thermocouples include E, J, K, N, and T, Bias: The intentional adjusting of a measuring device to correct for such things as; calibration error, SAT error or skewed TUS results. Calculated SAT Difference: The difference between corrected and uncorrected readings taken during an SAT as specified in Section 3.3 and Table 3.3.1 of this document. Calibration: A calibration is a comparison between the values indicated by a measuring instrument, ‘measuring system, or measuring device and the corresponding values realized by standards or field test equipment. See single-point calibration and multi-point calibration for further clarification As used herein, a calibration may also include verification that specified requirements, such as tolerances, performance, or other decision criteria have been met. Calibration may also include actions to take when requirements have not been met. Capabilit Carbon Restoration: A heat treat atmosphere process with the proper carbon potential that will restore the surface of the steel to the proper carbon content, It is usually performed on raw material that has decarburization at the surface. This is not to be used as a re-processing process. ‘The total range of inherent variation in a stable process. Continuous Furnace: Any furnace where product is conveyed continuously from the charge end to the discharge end, by way of example this would include continuous belt and pusher furnaces. Control Instrument: A device that operates automatically to regulate a controlled variable, Where the variable to be controlled is the temperature of process equipment the device is typically connected to a thermocouple. The process equipment would include ovens, furmaces, quench baths, and refrigeration equipment. The device may or may not also record temperature. Control Plans: Written descriptions of the system for controlling processes for production of parts or bbulk materials. Control Plans are written by organizations to address the important characteristics and engineering requirements of the process and product. Each part shall have a Control Plan, but in many ‘cases, “family” Control Plans may apply to a number of parts produced using a common process. -89-cats AIAG 2m Version 3, Issued 10/2011 Tho catayst or peak partorrance Control Thermocouple: A thermocouple connected to the temperature control i equipment. trument of the process Control Zone: That portion of the working zone in thermal processing equipment having a separate control thermocouple, control instrument and heat input/output device to control its temperature. Controlled Temperature Liquid Bath: Thermal processing equipment containing a liquid that is heated to the desired temperature. Product is normally immersed in the liquid. Corrected Reading: Data that has been adjusted to compensate for known error in the test equipment and/or test sensor(s) either by electronic methods or mathematical correction. Corrected data. Corrected Temperature: See Corrected Reading, Correction Factor: The number of degrees determined from the most recent calibration that is added to the temperature reading of a thermocouple, or an instrument or a combination thereof (system) to obtain true temperature. In the context of this document a correction factor is the algebraic opposite of error/de\ of error/deviation will result in a correction factor of -2.0°C). Critical Spare Parts Lists A list of service parts critical for the operation of equipment. Extended delay in obtaining spare parts woutd result in unacceptable delays in the heat treat option. Cross-Funetional Team: A team of employees that represent the different functions within an organization. The team will typically consist of an operator, line supervision, process engineer, ‘metallurgist, and quality personnel, Customer: The recipient of the organization’s or supplier's product or service. Customer Requirements: This term refers to the requirements or specifications from the original equipment manufacturer (typically the automobile company). These may be identified in the contract or purchase order, in engineering standards, part specifications, ete. Cycling: A periodic repeated variation in a controlled variable or proc Pattern, ss action. See Temperature Deviation: In the context of this document, the difference between the uncorrected indicated temperature and the true temperature, See Error. Degradation: The gradual shift of an attribute or operating characteristic that may lead to a point where the device can no longer fulfill its intended purpose. The degradation of thermocouples for example, is ‘commonly accelerated by their unprotected exposure to atmospheres typically found in industrial process applications (e.g. lack of protection tube where one is required or a damaged protection tube, etc.). Dew Pointer: A meter especially suited for measuring the dew point of carbon-bearing atmospheres. Dew point is used to indirectly determine the carbon potential of the atmosphere. Digital Instrumentation: An ifstrument that displays or presents the values of process variable ‘measurements in a digitized form. Energy Monitor: An electronic monitor that measures and displays the actual energy delivered to the induction heating coil Error: In process instrumentation, the algebraic difference between the indication and the true value of the measured signal,