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MINUTES OF MEETING
Date 28-Aug-18
NPD
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Refer the attached "Furniture Tests.xls" document for the no. of required tests as per BIFMA
standards and the no. of test knowledge handed over to QLE. Mr.Ravichandran /
1 Mr.Ashwin Whenever required for first time testing
Other than the knowledge shared tests, whenever new tests to be conducted, QA
Mr.Ravichandran / Mr.Ashwin to support for the first time of testing.
FDA SUPPORT
Additional / New Endurance Test Setup to be developed that has to be improved (Robust) from
the currently available one.
To accommodate bigger size chairs and following testings:
i) Structural durability
Mr.Paul Manoj / Date shall be fixed
ii) Tilt Mechanism - More Stroke length required (Maximum tilt limit of the chairs shall be shared
3 Mr.Vadivel when required
to FDA)
iii) Arm Strength Test - Vertical and Horizontal - Static and Cyclic FDA drawings are shared
iv) Leg Strength Test
Mr.Paul Manoj /
4 Rear Stability & Front Stability Test - Loading disks, support fixture and Template required as per Mr.Vadivel 15-Sep-18
BIFMA X5.1 standard.
FDA
5 Timing belt required for the Swivel test Mr.Vadivel - FDA 7-Sep-18
6 Commissioning reports and Manuals for all test equipment to be resubmitted to PLE by FDA Mr.Vadivel - FDA 4-Sep-18
PLE SUPPORT
Caster Wheel Testing:
Concrete test floor to be repaired - Recoating to be done.
Four leg frame to be provided as like below photograph for equal weight loading in 4 wheels
Mr.Senthil Prasad /
7 Mr.Arul Immediate
PLE
Page 1 of 16
CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When
performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related
Item # CSA Question Category/Process Steps Control Monitoring
#
1.0 ABRASIVE BLAST PROCESS
There shall be an incoming part assessment
B1.1 1.4 Per Control Plan Per lot
procedure with criteria.
The following checks shall be performed during
B1.2 2.11
production:
1.4
1.6 Per Control Plan/Log
B1.3 Abrasive media flow Automatic/Manual
2.11 Sheet (1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log
B1.4 Nozzle air pressure Automatic/Manual
2.11 Sheet (1/shift minimum)
2.12
1.4
1.6 Per Control Plan/Log
B1.5 Dwell time Automatic/Manual
2.11 Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
B1.6 2.11 Dust collector efficiency/air flow Automatic
Sheet (2/shift minimum)
2.12
1.4
Per Control Plan/Log
B1.7 2.11 Working mix Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
Surface profile is checked after process (if
B1.9 2.11 Manual Per lot
applicable).
2.13
CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.0 Pre-Electrocoat Paint Application Part Appearance
1.4 Incoming parts are inspected for cleanliness and/or uniform Per Control Plan/Log
E1.1 Manual
2.11 phosphate coating (when phosphate is used). Sheet (1 per hour)
2.0 Electrocoat Laboratory
E2.1 2.14 Laboratory equipment is calibrated and in good working order. N/A
Laboratory records, internal and external, are filed and accessible Per Control Plan/Log
E2.3 2.14 N/A
for review. Sheet (1/shift minimum)
3.0 Electrocoat Tank
1.4
Bath parameters (pH, conductivity, solid content, temperature, Per Control Plan/Log
E3.1 2.11 Automatic/Manual
voltage) are checked and adjusted. Sheet
2.12
1.4
1.6 Per Control Plan/Log
E3.2 Line speed setup is checked. Automatic/Manual
2.11 Sheet
2.12
1.4
E3.3 2.11 Line speed is verified. Manual Once/week minimum
2.12
1.4
There is circulation and it is monitored. (flow meter, pressure Per Control Plan/Log
E3.4 2.11 Automatic/Manual
gage) Sheet (1/shift minimum)
2.12
1.4
Bag filter pressures are monitored. Bags changed when psi Per Control Plan/Log
E3.5 2.11 Automatic/Manual
differential. >5-10 PSI. Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
E3.6 2.11 Flow direction is checked (for monorail system). Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan (1/shift
E3.7 2.11 Flow over the weir is checked. Manual
minimum)
2.12
1.4 Per Control Plan/Log
E3.8 2.11 Bath is checked for microbial contamination. Manual Sheet (1/ per week
2.12 minimum)
1.4
Per Control Plan/Log
E3.9 2.11 Incoming DI / RO water is checked for cleanliness. (conductivity) Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
1.17
E3.10 Paint racks are being maintained. Automatic/Manual As needed
2.11
2.12
1.4
1.17
E3.11 There is a paint rack maintenance schedule. Manual Required
2.11
2.12
1.4
1.17 Required (1/year
E3.12 There is a tank clean up schedule. Manual
2.11 minimum)
2.12
CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
4.0 Anolyte System
1.4
The anolyte solution is being controlled within the required Per Control Plan/Log
E4.1 2.11 Automatic/Manual
conductivity limits. Sheet (1/shift minimum)
2.12
1.4
The conductivity reading on the anolyte tank has been confirmed Per Control Plan/Log
E4.2 2.11 Automatic/Manual
in the laboratory. Sheet 1 / week
2.12
1.4
Per Control Plan/Log
E4.3 2.11 The pH of the anolyte solution has been checked. Automatic/Manual
Sheet (1 per shift)
2.12
1.4
Per Control Plan/Log
E4.4 2.11 Anodes have been inspected. Manual
Sheet (1 per six months)
2.12
1.4
Per Control Plan/Log
E4.5 2.11 The anolyte solution is being circulated to each cell. Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
E4.6 2.11 Dump and clean schedule for anolyte being maintained. Manual
Sheet
2.12
1.4
Per Control Plan/Log
E4.7 2.11 Amperage draw has been checked on each anode. Automatic/Manual
Sheet
2.12
5.0 Rectifier
1.4
1.6
E5.1 The proper voltage is being used for the load size. Manual per Equip. Mfg.
2.11
2.12
1.4
Per Control Plan/Log
E5.2 2.11 The ramp up time to full voltage has been verified. Automatic/Manual
Sheet (1 per shift)
2.12
There is a safety beacon to alert personnel when system is
E5.3 2.10
energized.
1.4
1.17 The ripple of the rectifier has been checked by an approved Per Control Plan / material
E5.4 Automatic/Manual
2.11 electrician. supplier
2.12
6.0 Rinse System
1.4
Immersion rinse tanks are operating at the proper levels and Per Control Plan/Log
E6.1 2.11 Automatic/Manual
tanks are being agitated correctly. Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
E6.2 2.11 There is sufficient permeate supplied to the rinse. Automatic/Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan/Log
E6.3 2.11 The pH and conductivity of the rinse have been recorded. Manual
Sheet (1/shift minimum)
2.12
1.4
Per Control Plan / material
E6.4 2.11 There is microbial testing of rinses. Manual
supplier
2.12
1.4
The ultrafilters are operating at proper pressures and bag filters Per Control Plan/Log
E6.5 2.11 Automatic/Manual
are being used. What size bags? Sheet (1/shift minimum)
2.12
1.4
1.17 Per Control Plan / material
E6.6 Rinses have been cleaned per maintenance schedule. Manual
2.11 supplier
2.12
7.0 Cure (See Convective Cure Process Table I)
CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.0 Part Appearance
Incoming parts are inspected for cleanliness, trapped water or
1.4 Per Control Plan/Log Sheet
F1.1 water spots as well as uniform phosphate coating (when Manual
2.11 (1 per hour)
phosphate is used).
1.4 Mutilation prevention items (i.e. gloves, belt buckle covers, watch
F1.4
2.9 covers, etc.) are in place.
1.4
1.17
F1.5 Paint racks are maintained. Manual
2.11
2.12
CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
2.0 Paint Mixing
1.4 Paint mixing rooms are controlled (mixing tank grounding, closed
Per Paint Manufacturer
F2.1 2.11 container, properly enclosed space, temperature, clean Automatic/Manual
Recommendation
2.12 environment).
1.4
Per Paint Manufacturer
F2.2 2.11 FIFO system is being utilized. Manual
Recommendation
2.12
1.4
1.6
Paint agitation/time and reduction (solvent package) are proper Per Paint Manufacturer
F2.3 1.17 Manual
and documented. Recommendation
2.11
2.12
1.4
1.6 Per Control Plan/Log
Viscosity and temperature are in operational limits and
F2.4 1.17 Manual Sheet/Paint Manufacturer
documented.
2.11 Recommendation
2.12
1.4
1.6 Per Control Plan/Log
F2.5 1.17 The proper filter size and type are in place. Manual Sheet/Paint Manufacturer
2.11 Recommendation
2.12
1.4
1.6 Per Control Plan/Log
F2.6 1.17 Pump pressures are set within operational limits. Manual Sheet/Paint Manufacturer
2.11 Recommendation
2.12
1.4
F2.7 2.11 Circulation (flow meter, pressure gage) is monitored. Automatic/Manual Per Control Plan/Log Sheet
2.12
1.4
Bag filter pressures are monitored (bags are changed when psi
F2.8 2.11 Automatic/Manual Per Control Plan/Log Sheet
differential >5-10 PSI).
2.12
CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
Substrate Conditioning (Flame, Plasma, etc) (If
3.0
applicable)
1.4 Incoming parts are inspected to ensure that they are free of dirt
F3.1 Manual
2.11 and contamination.
1.4
Per control plan and
1.17 2.11 Flame/Plasma is set at operational limits per equipment and
F3.2 Automatic equipment and substrate
material supplier recommendations.
suppliers recommendations
2.12
1.4
F3.3 2.11 Final surface tension is within specifications. Manual Per Control Plan
2.13
4.0 Primer/Promoter
1.4 Incoming parts are inspected to ensure that they are free of dirt Per Control Plan/Log Sheet
F4.1 Manual
2.11 and contamination. (1/shift minimum)
1.4
1.17 Per Control Plan/Log Sheet 1
F4.2 Destaticizing air is operational. (Plastic parts only) Automatic
2.11 / week
2.12
1.4
Per Control Plan/Log Sheet 1
F4.3 2.11 Booth balance is monitored. Manual
/ week
2.12
1.4
1.6
Booth temperature and humidity are monitored (or set within Per Control Plan/Log Sheet
F4.4 1.17 Automatic/Manual
operational limits if controlled). (1/shift minimum)
2.11
2.12
1.4
Per control plan and
F4.5 2.11 Film thickness is per customer requirements. Manual
customer requirements
2.12
1.4
1.6 Atomizer parameters (fluid flow, air pressures (atomizing fan,
Per Control Plan/Log Sheet
F4.6 1.17 shaping), electrostatics and mixing) are set within operational Automatic/Manual
(1 per month minimum)
2.11 limits.
2.12
CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
5.0 Basecoat (If applicable)
Per Control Plan / material
1.4 Incoming parts are inspected to ensure that they are free of dirt
F5.1 Manual supplier (once per shift
2.11 and contamination.
minimum)
1.4
1.6 Flashtimes between coats are set at suppliers recommended Per Control Plan/material
F5.2 Automatic/Manual
2.11 times. supplier
2.13
1.4
1.6
Booth temperature and humidity are monitored or set within Per Control Plan/Log Sheet
F5.3 1.17 Automatic/Manual
operational limits if controlled. (Required for waterborne coatings) (1/shift minimum)
2.11
2.12
1.4
1.6 Atomizer parameters (fluid flow, air pressures (atomizing fan,
Per Control Plan/Log Sheet
F5.4 1.17 shaping), electrostatics and mixing) are set within operational Automatic/Manual
(1 per month minimum)
2.11 limits.
2.12
1.4
Per Control Plan and
F5.5 2.11 Film builds are per supplier recommendations. Manual
suppliers recommendations
2.13
6.0 Basecoat Heated Flash (Waterborne Materials Only)
1.4
1.6 Set point is at suppliers recommended time, temperature and Per Control Plan / material
F6.1 Manual
2.11 energy type (convection/IR/UV/etc.). supplier
2.13
1.4
1.6 Percent solids after pre-dry is at the suppliers recommended Per Control Plan/Log Sheet
F6.2 Manual
2.11 percentage. (1/shift minimum)
2.13
1.4
1.17 Per Control Plan / material
F6.3 The pre-dry oven is maintained. Manual
2.11 supplier
2.12
CQI-12
Special Process: Coating System Assessment
Version 1, Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the
auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
7.0 Clearcoat
Per Control Plan / material
1.4 Incoming parts are inspected to ensure that they are free of dirt
F7.1 Manual supplier (once per shift
2.11 and contamination.
minimum)
1.4
1.6 Flashtimes between coats are set at suppliers recommended Per Control Plan/material
F7.2 Automatic/Manual
2.11 times. supplier
2.13
1.4
1.6
Booth temperature and humidity are monitored or set within Per Control Plan/Log Sheet
F7.3 1.17 Automatic/Manual
operational limits if controlled. (Required for waterborne coatings) (1/shift minimum)
2.11
2.12
1.4
1.6 Atomizer parameters (fluid flow, air pressures (atomizing fan,
Per Control Plan/Log Sheet
F7.4 1.17 shaping), electrostatics and mixing) are set within operational Automatic/Manual
(1 per month minimum)
2.11 limits.
2.12
8.0 Cure (See Convective Cure Process Table I)
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job
audit, the auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.4 After pretreatment, parts are inspected for flash rust, Per Control Plan/Log Sheet
G1.1 Manual
2.11 wetness, oil or other defects. (each lot)
1.4 If phosphated, parts are checked for uniformity of Per Control Plan/Log Sheet
G1.2 Automatic/Manual
2.11 phosphate coating. (1/shift minimum)
2.9
G2.5 Paint is kept covered and/or sealed when not in use. Manual Ongoing
2.10
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job
audit, the auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.4
Per Control Plan/Log Sheet
G2.10 2.11 Viscosity. Manual
(3/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
G2.11 2.11 % Solids (by weight). Manual
(1/Day minimum)
2.12
1.4
Per Control Plan/Log Sheet
G2.12 2.11 Volume (paint depth in coating vat). Automatic/Manual
(3/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
G2.13 2.11 Vibratory feed tables are cleaned (if used). Manual
(as needed)
2.12
1.4
1.17 2.11 Basket condition (basket mesh clean and Per Control Plan/Log Sheet
G2.14 Manual
undamaged). (as needed)
2.12
1.4
Per Control Plan/Log Sheet
G2.15 2.11 Paint and/or solvent additions are documented. Manual
(each addition)
2.12
2.14
G2.17 Viscosity cups are verified. Manual 2/Month minimum
1.17
2.14
G2.18 Thermometers are calibrated/verified. Manual Once/Month minimum
1.17
CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job
audit, the auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.4
G3.5 1.6 The coating unit has an attached RPM indicator.
1.17
1.4
G3.6 1.6 RPM's can be adjusted easily.
1.17
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job
audit, the auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.4 Tumble time is in/out of coating controlled (if Per Control Plan/Log Sheet
G3.9 Automatic/Manual
1.6 applicable). (each lot)
1.4
There is an adequate system to keep parts level going Per Control Plan/Log Sheet
G3.10 1.6 Automatic/Manual
into the oven (raking, vibe table, etc.). (each lot)
1.17
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit,
the auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.4
Per Control Plan/Log Sheet
H1.6 2.11 101 (fluoride) and ORP levels are checked. Automatic/Manual
(every 2 hours minimum)
2.12
1.4
Chemical concentration (% solids, starter/iron Per Control Plan/Log Sheet
H1.7 2.11 Automatic/Manual
titration, conductivity) is checked and maintained. (1/shift minimum)
2.12
1.4
1.17 Per PM schedule
H1.8 Bath transfer is maintained. Manual
2.11 (1/year minimum)
2.12
2.0 1.18 Tap Rinse After Coating
1.4
Per Control Plan/Log Sheet
H2.1 2.11 Pump pressure or agitator speed is monitored. Automatic/Manual
(1/shift minimum)
2.12
1.4
Per Control Plan/Log Sheet
H2.2 2.11 Impurity concentration (conductivity) is checked. Automatic/Manual
(1/shift minimum)
2.12
CQI-12
Special Process: Coating System Assessment
Version 1 Issued 8/07
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit,
the auditor shall verify coater is conforming to customer requirements.
Related
Item # Category/Process Steps Control Monitoring
CSA Question #
1.4
Per Control Plan/Log Sheet
H3.2 2.11 Pump pressure or agitator speed is monitored. Automatic/Manual
(1/shift minimum)
2.12
1.4
Temperature is monitored and controlled (if Per Control Plan/Log Sheet
H3.3 2.11 Automatic/Manual
applicable). (1/shift minimum)
2.12
1.4
1.17 Per Chemical Manufacturer's
H3.4 There is a dump schedule. Manual
2.11 Guideline (minimum 3 times per year)
2.12
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
PROCESS EQUIPMENT
Related Powder Calibration
Item # Pretreatment E-Coat Spray Dip/Spin A-Coat Cure Verification Frequency Comment
CSA Question # Coat Frequency
1.1 2.14 X X X X X pH Meter/Probe Daily Yearly
1.2 2.14 X X X X X X X Temperature Controller At Start-up 2x/Year
1.3 2.14 X X Rectifier At Start-up N/A
Phosphate - 3hr min.
1.4 2.14 X X X X X Wet Analysis Paint Lines - Before Run N/A
E-Coat - 1x/Shift min.
1.5 2.14 X Atomic Absorption (Optional)
1.6 2.14 X X X X X X X Filters * N/A * As needed based on pressure.
1.7 2.14 X X X Balance 1x/Week Yearly
1.8 2.14 X X Coductivity Meter Before Use Yearly
1.9 2.14 X X Viscosity Measurement Hourly Monthly
1.10 2.14 X Thermocouple N/A 2x/Year
MINIMUM REQUIRED TESTING CAPABILITY
2.1 2.14 X X X X X X Salt Spray Cabinet
2.2 2.14 X X X X X Water Immersion Tank
2.3 2.14 X Environmental Chamber
2.4 2.14 X Cure Testing (chemical rubbing)
2.5 2.14 X X X X X X Adhesion Testing
2.6 2.14 X X X X X X Thickness Testing
2.7 2.14 X X X X X X Microscope (when applicable)
2.8 2.14 X Freezer (plastic substrate)
2.9 2.14 X Lab Oven