Special Process Audit Check Sheet - Plating
Special Process Audit Check Sheet - Plating
To :
Supplier Name :
Route Supplier Quality Assurance incharge :
Audit person
Approval
1.I announce the audit result of process quality audit carried out on We expect you to utilize this as improvement data of your company and to clarify the
improvement plan as for the indicated matters to submit it to Purchase dept.
Purchase
2. Auditee :
Supplier
Duplicate
QA
3. Audit Person :
4. Evaluating Point
(Original paper)
(Copy)
(Copy)
Rank A B C D E
Characteristic
Classification 75 or more to 60 or more to 45 or more to
Evaluating point 90 or more Less than 45
less than 90 less than 75 less than 60
2) Conclusion of Evaluation
3 Loading / 55 19 Adhesiveness / 10
16 Inspection process / 60 /
2) Special decreased point (When a serious defect on the quality control is found as a result of the audit, evaluation level is decreased to unsuitable rank. Special
decreased point will be vanished if the defect is improved within six months.)
Approved
Special
0
decreased point
5. Comment :
Quality Assurance
Reviewed
Evaluation criteria : Good = 80 to 100% satisfaction, Average = 50 to 80%, Not good = 20 to 50%, Bad = 0 to 20%
Evaluation score
Sl.No. Process Control Check items Supplemental description Reason of checks KMSI Observation Result
Not Score
Good Average Bad
good
Confirm that prevention action for
Material If there is distribution warehouse, Confirm that first in first out and rust is to be placed and unnecessary 5 3 1 0
confirm that lot control is to be placed. rust prevention are to be placed.
stock is to be kept.
Packing style Confirm that tag and delivery (In case of different department 5 3 1 0
document are attached. receive material.)
Confirm that prevention action of
Packing style Confirm that tag and delivery parts (In case of different department mixture parts and miss count are to 5 3 1 0
Plating parts name and quantity are same. receive material.)
1 be placed.
acceptance
Confirm that carrier is free from
Confirm that packing style prevent free play, hardening of insulator Confirm that the measure of scratch
Packing style and broken of partition. Confirm and knock mark and easy control 5 3 1 0
scratches.
that specification is to prevent method of number are to be placed.
parts from hitting each other.
Confirm that rust parts handling Rust parts should not be plated. Many
Training standard is decided. Question: Is Re-buffing specified? rust mark failure should be happened. 5 3 1 0
Confirm that a specified type of rust- Any oil remaining on the surface
Inspection Material preventive oil has been used. Select causes the product to become dirty, 5 3 1 0
2 before the type of low viscosity. producing a defect.
plating
Confirm that washing method for pipe Confirm that reserve cleaning or Washing pipe inside is difficult in
Operation inside is specified. steam cleaning is to be placed. ordinal plating process. Additional 5 3 1 0
cleaning before plating is necessary..
Confirm that the plating rack has not Rattling causes poor current carrying
Operation been loosened or rattled on hooking Thumbscrews and plate springs performance thus results in plating 5 3 1 0
must not be loosened.
on a copper bar. peeling.
In case of an electrolytic bath, confirm Care must be taken to ensure This item is required to control the
Process that the amount of impurity metals is that Fe, Cr and Cu amounts are conditions to assure the plating 5 3 1 0
below the specified level. below the specified levels. quality. This affects the adhesiveness.
They must flow into the If dirt or oil is accumulated near the
Confirm that no dirt or oil remains at bath outlet, products become dirty
Equipment overflow. Or the oil removal 5 3 1 0
the liquid level of cleaning bath. equipment must operate. while moving upward. This dirt is a
major cause of an oil defect.
Confirm that the oil pan has An oil defect occurs, when the current
Confirm that means have been
Equipment provided to ensure no grease dropped been provided, or that the carrying grease, the hoist grease or 5 3 1 0
procedure has been specified for the chain grease is dropped into the
into the bath. grease application. bath.
The purpose are to prevent
Process Confirm that the plan to replace of deterioration of solution and keep 5 3 1 0
pretreatment solution is specified.
performance.
Equipment Confirm that exchange of duct filters Confirm that there is no chemical To keep work environment. 5 3 1 0
are to be placed. mist and odor.
Equipment Confirm that the duct should be Confirm that there is no chemical To keep work environment. 5 3 1 0
confirmed its suction from inlet. mist and odor.
Confirm that the nozzle has not been Products must be exposed to
Equipment clogged. shower. For improving cleaning performance. 5 3 1 0
Plating
5 pretreatment
Water rinse Confirm that water volume control has Means for improving cleaning
Process been performed for shower water Valve position must be specified. 5 3 1 0
performance.
rinse.
Confirm that periodic inspections have Error between measured value Check for trouble and disorder of
Equipment and indicated value must be 5 3 1 0
been performed on the thermometer. meter.
within ±3ºC.
Confirm that means have been Ensure that oil receiver is When current carrying grease, hoist
Equipment provided to ensure no grease dropped available. Check the application grease, chain grease, etc. fall into the 5 3 1 0
into the bath. method of grease. bath, it results in defective oil.
Equipment Confirm that air bubble generation is Air bubble generation must not Uniform agitation keeps uniform film 5 3 1 0
constant in the entire bath. be stopped in any area. thickness and avoids pit failure factor.
Process Confirm that the current and the This is essential control item to keep 5 3 1 0
voltage are in the control range. plating quality.
Confirm that the inspection has been Means for finding a trouble of
performed on the remaining agents in Check the supply records, in case
Process the brightening agent supply tank, the agents have been supplied with a chemical injection pump. It maintains 5 3 1 0
the concentration of brightening
condition of the discharge pump or beaker.
agent constant.
piping clogging.
Temperature, concentration of
hexavalent chromium, trivalent
Process Confirm that the liquid condition is in chromium, sulfuric acid, and This is essential control item to keep 5 3 1 0
the control range. other additives must be within plating quality.
the control range, or must be
corrected.
Pay attention to Fe, Nl, chlorine, This is essential control item to keep
Confirm that impure metals amount is plating quality. When these
Process below the specified limit. and Cu. When they increase, substances increase, adhesiveness of 5 3 1 0
adhesiveness of Cr deteriorates.
Cr deteriorates.
Confirm that means have been Ensure that oil receiver is When current carrying grease, hoist
Equipment provided to ensure no grease dropped available. Check whether grease grease, chain grease, etc. fall into the 5 3 1 0
into the bath. application method is specified. bath, it results in defective oil.
Confirm that exhaust filter has been Chemical mist must not fly about
Equipment To secure working environment. 5 3 1 0
replaced. and must be free from odor.
Confirm that suction can be identified Chemical mist must not fly about
Equipment To secure working environment. 5 3 1 0
at the opening of the exhaust hood. and must be free from odor.
Confirm that the current and the This is essential control item to keep
Process 5 3 1 0
voltage are in the control range. plating quality.
7 Cr plating Confirm that anodes have been placed Anode case must be placed at When it is too far from the product,
Process at uniform intervals. the front of the jig. film thickness is not ensured. 5 3 1 0
Confirm that the analysis data has Data is easy to see. Improvement item
Process been in the form of a graph to enable 5 3 1 0
of control.
visual inspection of control conditions.
Confirm that no dirt or oil has floated Dirt or oil is designed to flow into Means for improving cleaning
Equipment at the liquid level in the water rinse 5 3 1 0
overflow. performance.
bath.
Cr plating
8 Confirm that shower water contacts
Water rinse Process For improving cleaning performance. 5 3 1 0
the product.
Confirm that the shower nozzle has The product must be exposed to
Equipment For improving cleaning performance. 5 3 1 0
not been clogged. shower.
Confirm that the impurity metal Pay attention to Fe, Cr, Cu, and This is a control item to keep plating
Process amounts are below the specified limit. chlorine content. If they quality. 5 3 1 0
increase, glossiness is lost.
Confirm that the inspection has been Means for finding a trouble of
Process performed on the remaining agents in chemical injection pump. It maintains 5 3 1 0
the brightening agent supply tank or the concentration of brightening
the condition of the discharge pump. agent constant.
Confirm that the pH measurements When pH is out of control range, This is essential control item to keep
Process have been performed at least every 4 it is impossible to provided 5 3 1 0
plating quality.
hours. normal glossiness.
pH, temperature, Fe
Process Confirm that the liquid condition is in concentration, and Zn 5 3 1 0
the specified control range.
concentration
pH measurement must be
Confirm that periodic calibrations have
Process been performed on the pH measuring calibrated at least once a month. 5 3 1 0
In addition, the electrode must
instrument.
not be contaminated.
Confirm that the rule has been Do not touch a product with bare
Operation established to wear dedicated gloves. hand or contaminated gloves. 5 3 1 0
Confirm that the hot rinse (For hot rinse process) The If a product is not dried, rusting is
Process temperature must allow drying 5 3 1 0
temperature is in the control range. caused by moisture.
of products after hot rinsing.
Instrument
14 Instruction manual of measuring
condition
Confirm that the periodic calibrations Last calibration day is within one instrument specifies that calibration
Quality have been performed on the year as well as the calibration before measurement is necessary. It is 5 3 1 0
inspection instrument. interval is specified. necessary to specify the frequency
and rule and observe them.
Confirm that the periodic evaluations Check whether a record is Check whether hardness is within
Quality available. Check whether 5 3 1 0
have been performed on the hardness. hardness is within tolerance. product drawing tolerance.
Confirm that the rule has been Storage and handling method of
Quality established to operate any instrument 5 3 1 0
equipment must be available.
dedicated for inspection.
Confirm that correct markings have Kanban display must be To prevent mixing of foreign parts, or
Packing style been provided on both finished and available. Stock area must be 5 3 1 0
defective products. specified. wrong quantity.
Confirm that the check items and Check items and frequency must be
Quality frequency have been specified for indicated on the work standard 5 3 1 0
inspection. pursuant to inspection standard.
Confirm that the rule has been Correction method and sorting
Quality established to handle the rejected method must be provided in For preventing mixing. 5 3 1 0
products. text.
Confirm that periodic inspections have Last inspection day is within one
Quality been performed on the film thickness year as well as the inspection 5 3 1 0
meter. interval is specified.
Confirm that the rinse procedure has Dissolve deposited metal content Careful procedure and simple
with diluted sulfuric acid. Anode procedure are available, and they
Process been specified for mats for 5 3 1 0
precipitates at the bath bottom. bag must be kept free from dust relate to cleaning frequency. There
in storage. should be a rule preferably.
Confirm that a skilled operator, who Analysis is the most important skill for
Training completed the training course, is in Question "Is dripping possible?" controlling the concentration of 5 3 1 0
charge of analysis. plating liquid, and requires accuracy.
Material Confirm that the inventory control has Control in a chemical stockroom To prevent theft. 5 3 1 0
been performed on analysis reagents. that can be locked.
Confirm that the corrective measures Check the measure and plan
Quality have been taken based on the defect starting from failure items having 5 3 1 0
record. a high failure rate.
Defective
Check whether defective
product Confirm that the rule has been
26 handling Quality established to correct the defects. products are isolated and For preventing mixing. 5 3 1 0
indicated.
procedure
Jig Confirm that the strength is enough to For level checks, refer to the 5 3 1 0
27 Plating jig hold a work in place. design specification.
Confirm that a operator has checked Free from leakage, and damage
Equipment the conditions of each bath. to liquid level/FRP. 5 3 1 0
Confirm that periodic inspections have Check for break of pilot lamp and
Equipment 5 3 1 0
been performed on the control panel. trouble of control circuit.
Check by appearance. If an
Confirm that a variety of contacts at When the contact is contaminated,
infrared thermometer is
Equipment the anode and the cathode have been electrification is poor, and normal 5 3 1 0
available, check whether the
cleaned periodically. treatment is impossible.
temperature is within 100ºC.
Confirm that the inspection has been There must be a criteria for filter Maintenance and control of
Equipment performed on the blower. and belt. equipment. 5 3 1 0
Confirm that the rule has been Check whether the standard of
Equipment established to control the electrical For maintaining the cleanliness of
31 associated Equipment replacement (upper limit of 5 3 1 0
conductivity in the ion exchange liquid.
with lines tower. conductivity) is specified.
Confirm that clogging of pipes does Perform the control based on the
Piping and valve, when used long, also
Process not cause a significant reduction in the pressure. If pressure is applied cause clogging phenomenon. It affects 5 3 1 0
amount of liquid flowing through the even to a new filter cloth, check
filter. piping for clogging. quality failure.
Confirm that the inspection has been Free from contamination and
Equipment For ensuring working environment. 5 3 1 0
performed on a duct in each bath. leakage.
(Form 4)
Tick in . Audit Observation follow up sheet
Supplier name Audit purpose and method
Schedule / Plans submission Follow implement planning (Completion target: Completed less than three months from audit implemented date) KMSI reference No.
System Voluntarily performance follow
M/S
[Schedule]
Process KYB Performance [ ] [ ] [ ] [ ] [ ] Audit implement date
Submission date
Submission to KMS
Reviewed
Reviewed
Approved
Approved
Supplier
Supplier
Check
Charge
Charge
Quality
Date Month Year
* Please fill in and submit "improvement plan" by the above-mentioned date* Supplier should fill in heavy line frame. * If improvements are completed, please fill in and submit "implement result" promptly.