Special Process: Heat Treat Process Assessment特殊过程：热处理过程评估 |
| | | | | | | | |
| | | | | Assessment 评估 |
| Question Number | Question问题 | Requirements / Guidance要求/指导 | Objective Evidence客观证据 | N/A 不适合 | Satisfactory
满意 | Not Satisfactory
不满意 | Needs Immediate Action 需要立即改进 |
Section 1 - Management Responsibility & Quality Planning管理职责&质量计划 |
| 1.1 | 现场是否配备有资格的热处理专业人员? | ·全职、在册员工
·具备冶金和热处理专业知识
·至少5年热处理操作经验或至少5年基础冶金教育及热处理经验 | | | | | |
| 1.1 | Is there a dedicated and qualified heat treat person on-site? | To ensure readily available expertise, there shall be a dedicated and qualified heat treat person on site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including metallurgical and heat treat knowledge. The qualifications shall include a minimum of 5 years experience in heat treat operations or a combination of a minimum of 5 years of formal metallurgical education and heat treat experience. | | | | | |
| 1.2 | 是否进行热处理的先期质量策划？（APQP） | ·有APQP程序，每个零件进行了可行性研究和内部批准
·相似零件能够组成零件族并得到定义
·PPAP后，无顾客 未批准的过程更改
·重大过程更改的澄清应联系顾客并保持记录 | | | | | |
| 1.2 | Does the heat treater perform APQP? | The organization shall incorporate a documented Advance Product and Quality Planning (APQP) procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the Production Part Approval Process (PPAP) is approved by the customer, no process changes are allowed unless approved by the customer. The heat treater shall contact the customer when clarification of process changes is required. This clarification of significant processes change shall be documented. | | | | | |
| 1.3 | PFMEA‘s是否得到更新，并与目前的过程相一致？ | ·具有文件化的PFMEA管理程序并确保PFMEA得到更新以反映当前零件的质量状态
·PFMEA’s适用与每个零件或零件族，体现了从接收到发运的所有过程步骤和所有关键的过程参数
·有组织或顾客确定的重要或关键特性应得到识别、定义和体现在FMEA’s中
·应有包括生产操作者在内的跨功能小组来开发PFMEA
·每年应考虑解决高的风险系数（RPNS）的项目 | | | | | |
| 1.3 | Are heat treat PFMEA's up to date and reflecting current processing? | The organization shall incorporate the use of a documented Process Failure Mode and Effects Analysis (PFMEA) procedure and ensure the PFMEAs are updated to reflect current part quality status.
The PFMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key heat treat process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of the PFMEA, and items with the highest Risk Priority Numbers (RPNs) shall be addressed annually. All significant or critical characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the PFMEA. | | | | | |
| 1.4 | 控制计划是否得到更新，并与目前的过程相一致？ | ·具有文件化的控制计划管理程序确保控制计划得到更新，以反映当前的控制
·使用于每个零件或零件族，体现了从来料接收到零件发运的所有过程步骤、所有关键的过程参数和所使用的设备
·应有包括生产操作者在内的跨功能小组来开发控制计划
·与作业指导书（Work Instructions)、工艺流程卡（Shop travelers）、PFMEA‘s保持一致性
·由组织或顾客确定的重要或关键特性应得到识别、定义和体现
·针对过程和产品特性评估的样本大小和抽样频率应该与该过程表中的3.0和4.0节中的最低要求保持一致 | | | | | |
| 1.4 | Are heat treat process control plans up to date and reflecting current processing? | The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls.
The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key heat treat process parameters as defined by the organization.
A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and PFMEAs. All significant or critical characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables, Sections 3.0 and 4.0. | | | | | |
| 1.5 | 所有相关的或引用的规范是否为最新的和可用的？包括但不限于：SAE、AIAG、ASTM、GM、FORD、DC等 | ·所有相关的或引用的规范应是最新的和可用的。包括但不限于：SAE、AIAG、ASTM、GM、FORD、DC等
·应有一个形成文件的过程，适时评审、分发和执行顾客的工程标准和规范（Customer requirments），该过程一般不超过两周，文件规定由谁、如何得到、如何维护、如何建立最新状态跟踪和如果传递到生产现场？ | | | | | |
| 1.5 | Are all heat treat related and referenced specifications current and available? For Example: SAE; AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. | To ensure all customer requirements are both understood and satisfied, the organization shall have all related heat treat and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all relevant customer and industry engineering standards and specifications. This process shall be executed as soon as possible and shall not exceed two weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks. | | | | | |
| 1.6 | 对所有的操作过程是否有书面的过程规范？ | ·对所有的操作过程都应有书面的过程规范，并包含所有过程的步骤
·操作参数包括过程温度、时间周期、装载率、气氛流量设置、传送速度、淬火搅拌速度等，应确定其公差范围以便进行控制
·过程规范可以采用工作指导书、作业卡、计算机系统的参数设定表单（Computer-based recipes）或其它类似的文件形式 | | | | | |
| 1.6 | Is there a written process specification for all active processes? | The heat treater shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, atmosphere or gas flow settings, belt speeds, quench agitation speeds, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control.
All active processes should have a written process specification.
These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents. | | | | | |
| 1.7 | 生产初始阶段、过程设备重新布置和大修改造之后是否进行了有效的能力验证？
新购过程设备或重新布置或大修改造后的设备是否有效的完成了过程能力研究？ | ·为证明每一个过程能够生产出可接受的产品，供应商应对每一个过程进行生产能力研究，包括在初始验证、任何过程设备重新布置或大修（应定义何为大修）之后
·初始能力研究应包括指定了年度工作范围的每一条热处理炉生产线的热处理过程，一条热处理炉生产可能包括很多设备的组合以集成需要的热处理工艺，如硬化、淬火和回火
·能力研究技术应针对热处理产品特性参数是适当的，这些参数包括抗拉强度、硬化深度、硬度
·任何顾客的特殊要求均应满足，当没有顾客特殊要求时，应建立一个能力的接受准则（Acceptable ranges）以测量过程能力，一旦超过顾客的特殊要求和内部规定的接受准则时，应采取行动计划 | | | | | |
| 1.7 | Has a valid capability study been performed initially and after process equipment has been relocated, or had a major rebuild? | To demonstrate each process is capable of yielding acceptable product the organization shall perform product capability study for the initial validation of each process, after relocation of any process equipment, & after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all heat treat processes per furnace line defined in scope of work & annually thereafter. A furnace line may include a combination of equipment that is integrated in the performance of a heat treatment process, i.e. hardening, quenching, and tempering. Capability study techniques shall be appropriate for the heat treat product characteristics, i.e. tensile strength, case depth, hardness. Any specific customer requirements shall be met, in the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to followed in case capability indices fall outside customer requirements or established ranges. | | | | | |
| 1.8 | 是否针对整个过程搜集分析数据，并针对这些数据进行适当的反应？ | ·热处理产品和过程数据的分析能提供缺陷预防的重要信息
·应建立一个全过程收集、分析、和反映产品和过程数据的系统
·分析方法包括对重要产品和过程参数的现行趋势和历史数据的分析
·应确定哪些参数需要列入分析范围 | | | | | |
| 1.8 | Does the heat treater collect and analyze data over time, and react to this data? | The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time.
Methods of analysis shall include ongoing trend or historical data analysis of significant product or process parameters. The organization shall determine which significant parameters to include in such analysis. | | | | | |
| 1.9 | 管理者是否每24小时评审热处理炉监控系统（Furnace Monitoring Systems）？ | ·管理者应每24小时评审热处理监控系统
·监视包括但不限于：温度纸带记录、气氛纸带记录、计算机数据日志、热处理炉及操作者日志
·评审包括对失控状态或报警状态的探测。热处理炉数据的评审过程应进行记录，该记录要求同样适用于计算机数据 | | | | | |
| 1.9 | Is management reviewing the heat treat monitoring system every 24 hours? | Management shall review the furnace monitoring systems at intervals not to exceed 24 hours. The heat treat monitoring system includes but is not limited to temperature strip charts, atmosphere strip charts, computer data logs, furnace and operator logs, etc.
The management review shall include efforts to detect out-of-control conditions or alarm conditions. The process of reviewing the furnace data shall be documented and this requirement also applies to computerized data. | | | | | |
| 1.10 | 是否每年至少一次按AIAG的HTSA进行内部审核？ | ·每年最少一次按AIAG的HTSA进行内部审核，应及时发布审核时发现的问题点 | | | | | |
| 1.10 | Are internal assessments being completed on an annual basis, at a minimum, using AIAG HTSA? | The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG HTSA. Concerns shall be addressed in a timely manner. | | | | | |
| 1.11 | 是否有一个文件化的返工批准系统？ | ·应有一个文件化的返工（reprocessing）批准系统，包括对指定人的授权
·该程序应描述哪些产品特性允许，哪些不允许
·任何一个返工，需要有资格的技术人员编制一个新的过程控制表，表明热处理更改的必要性
·应记录何时、有多少材料被返工
·质量经理或指派的授权人员应批准再处理零件的发运 | | | | | |
| 1.11 | Is there a system in place to authorize reprocessing and is it documented? | The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual.
The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible.
Any reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary heat treat modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product. | | | | | |
| 1.12 | 针对顾客和内部关注的问题，质量部门是否评审、处理并形成文件？ | ·质量管理体系应包括一个针对文件化、评审和识别外部顾客关注和任何其他内部关注问题的过程
·可以采用有纪律的问题解决方法 | | | | | |
| 1.12 | Does the Quality Department review, address, and document customer and internal concerns? | The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used. | | | | | |
| 1.13 | 是否针对热处理审核范围内的每个过程，建立了适用的持续改进计划？ | ·应建立一个持续改进过程，适用热处理审核范围的每个过程，这些过程的设计应带来质量水平和生产率的持续改进
·行动计划应体现优先顺序和日期要求（完成时间）
·应提供该项目运行有效性的证据 | | | | | |
| 1.13 | Is there a continual improvement plan applicable to each process defined in the scope of the assessment? | The heat treater shall define a process for continual improvement for each heat treat process identified in the scope of the HTSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness. | | | | | |
| 1.14 | 质量管理者或指定的责任人是否批准对隔离材料进行处置？ | ·质量管理着有责任批准和文件规定适当的人员对隔离材料进行处置 | | | | | |
| 1.14 | Does the Quality Manager or designee authorize the disposition of material from quarantine status? | The Quality Manager is responsible for authorizing and documenting appropriate personnel to disposition quarantine material. | | | | | |
| 1.15 | 是否建立覆盖整个热处理过程适用于操作者的操作手册？ | ·应建立覆盖整个热处理过程（从接收到发运）的、适用的作业指导书（或操作手册）
·这些程序或作业指导书包括潜在情况（如动力中断）设备开动和停止、产品隔离、产品检验及一般操作程序
·这些程序或作业指导书应覆盖从原材料接收到产品发运的所有操作步骤并能由车间人员方便获取 | | | | | |
| 1.15 | Is there an operations manual available to heat treat personnel covering the entire heat treating process? | An operations manual shall be available to heat treat personnel covering the entire heat treating process. The manual shall include procedures or work instructions addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall cover all steps of the operation from product receipt to product shipment and shall be accessible to shop floor personnel. | | | | | |
| 1.16 | 管理着是否始终为所有热处理员工（包括后备的、临时的）提供培训？ | ·管理者必须始终为所有热处理员工（包括后备的、临时的）提供培训
·必须保持文件化的证明以表明员工得到了培训和进行了培训有效性的评估
·必须确定每项活动所需要的资格要求及现在和将来的培训需求 | | | | | |
| 1.16 | Is management providing employee training for heat treating? | The organization shall provide employee training for all heat treating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed. | | | | | |
| 1.17 | 是否建立责任矩阵表证明所有关键的管理和监控活动都由有资格的人员完成？ | ·应有可靠的责任矩阵表证明所有关键的管理和监控活动都由有资格的人员完成，对关键的活动，应规定主要和次要的人员
·管理层能在任何时候方便的获取该矩阵 | | | | | |
| 1.17 | Is there a responsibility matrix to ensure that all key management and supervisory functions are performed by qualified personnel? | The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times. | | | | | |
| 1.18 | 是否有预防性维护程序？预防性维护数据是否作为预测性维护计划的一部分？ | ·对识别的关键过程应建立一个预防性维护程序，该程序必须是一个从请求到实施到有效性评估的闭环，操作者有机会报告问题并在闭环中解决问题
·计算机数据如停机时间、质量拒收（QR）、FTT能力、重复维修指令、操作者问题报告均可用来改善预防性维护程序
·热处理炉和各类发生器应按照确定的频率制定相应的烧烬计划（详件过程表1.0）
·作为预见性维护计划的一部分，维护数据应得到收集并进行分析 | | | | | |
| 1.18 | Is there a preventive maintenance program? Is maintenance data being utilized to form a predictive maintenance program? | The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner.
Company data, e.g., downtime, quality rejects, first-time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Furnaces and generators shall be scheduled for burn-out at frequencies determined by the organization (see Section 1 of the Process Tables).
Maintenance data shall be collected and analyzed as part of a predictive maintenance program. | | | | | |
| 1.19 | 是否开发一份关键零部件备件清单（Critical Spare parts List)以能保证最小程度的生产中断？ | ·建立一份关键零部件备件清单，以保证最小程度的生产中断 | | | | | |
| 1.19 | Has the Heat Treater developed a critical spare part list and are the parts available to minimize production disruptions? | The heat treater shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions. | | | | | |
Section 2 - Floor and Material Handling Responsibility场地和材料搬运职责 |
file:///C:/DOCUME~1/ADMINI~1/LOCALS~1/Temp/msohtmlclip1/01/clip_image035.gif | ·是否确保输入接收系统的数据与顾客发运文件上的信息想一致？ | ·将所有的顾客要求和批次识别充分转化为内部热处理文件至关重要
·确保输入接收系统的数据与顾客发运文件的信息一致
·文件化的规定和符合证据如：工艺流转卡、工作订单等
·当存在接收材料不能准确的与发运文件相符合时，供应商应具有详细的流程来处理接收的差异。
·上述要求也同样适用于内部有热处理部门的情况，该过程中接收和发运参照执行 | | | | | |
| 2.1 | Does the facility ensure that the data entered in the receiving system matches the information on the customer's shipping documents? | It is critical that all customer requirements and lot identification be adequately transferred to internal heat treat documents. The facility shall ensure that the data entered in the receiving system match the information on the customer's shipping documents. Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. Sometimes the material received does not precisely correspond to customer shipping documents. The facility shall have a detailed process in place to resolve receiving discrepancies.
The requirements stated above also apply to captive heat treat departments. This process refers to receiving and shipping the parts in and out of the heat treat department. | | | | | |
| 2.2 | ·在热处理全过程中产品是否清楚地标识并实施？ | ·对产品和容器在热处理过程的标识进行规定以避免不正确的处理和混淆
·在工厂内部划分适当的场所（定置）和阶段管理可以保证在所有的工序未完成之前，订单产品是不会发运的
·顾客产品在热处理全过程中必须清楚地标识并在整个热处理过程中分阶段存储
·合格品、在制品、完工品应适当地分类和标识
·所有的材料均应放在一个被清楚鉴定的专门区域内分段运输 | | | | | |
| 2.2 | Is product clearly identified and staged throughout the heat treat process? | Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the heat treat process. Green, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area. | | | | | |
| 2.3 | 在热处理全过程中是否完整地维护的批次追踪和完整性？ | ·输出的批次能追溯到输入的批
·批次准确识别的原则和与批次相关信息的链接能提高分析根本原因和持续改进的能力 | | | | | |
| 2.3 | Is lot traceability and integrity maintained throughout all processes? | Out-going lot(s) shall be traceable to the incoming lot(s).
The discipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement. | | | | | |
| 2.4 | ·是否有足够的程序规定以防止不合格产品流入到生产系统？ | ·必须对可疑品或不合格品进行控制，以防止错误的发运和污染其它产品
·应有足够的程序规定用于防止不合格产品流入到生产系统
·应有文件规定适当的处理、产品标识以及原材料进出指定区域的跟踪
·应指定不合格存放区，以保持这类材料的隔离 | | | | | |
| 2.4 | Are procedures adequate to prevent movement of non-conforming product into the production system? | The control of suspect or non-conforming product is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification, and tracking of material flow in and out of the hold area. A non-conforming/hold area shall be clearly designated to maintain segregation of such material. | | | | | |
| 2.5 | 在整个热处理过程中是否有一个系统用于识别死角区，以减少零件混淆的风险（包括外来的、合格件、和不正确处理的零件）？ | ·在整个热处理过程中应有一个系统用于识别死角区，以减少零件混淆的风险（包括外来的、合格件、和不正确处理的零件
·应建立文件对每一个热处理过程/设备的死角区（trap points)进行识别和监控
·当每个零件的生产方法或装备改变时应识别潜在的死角区（trap points） | | | | | |
| 2.5 | Is there a system to identify trap points in the entire heat treat process to reduce risk of mixed parts (foreign, green, or improperly heat treated parts)? | Heat-treating furnaces and other processing equipment contain areas that have a risk of trapping or holding parts. Such trapping of parts can lead to damage, improperly processed parts or lot mixing/contamination. A system shall exist to identify trap points in the entire heat treat process to reduce risk of mixed parts (foreign, green, or improperly heat treated parts). The heat treater shall have documented procedures to identify and monitor trap points for each process/equipment. Monitoring of potential trap points shall occur for every part changeover. | | | | | |
| 2.6 | 容器内是否摆脱了外来材料的影响？ | ·装有顾客产品的容器内应无外来材料的影响
·必须检查容器中的外来材料并通报其来源
·在容器空出或再使用后应检查是否还有未经热处理的零件，以防污染已完工产品 | | | | | |
| 2.6 | Are containers free of foreign material? | Containers handling customer product shall be free of foreign material. Containers shall be inspected for foreign material and the source of the foreign material shall be notified. After emptying and before re-using containers, containers shall be inspected to ensure that all parts have been removed. This is to ensure that no green (un-heat treated) parts contaminate the finished lot. | | | | | |
| 2.7 | 是否建立装炉操作规范、作业文件并加以控制？ | ·应建立装炉操作规范、作业文件并加以控制
·装炉参数包括：进料速度、传动带速度、每筐的零件数、装裁重量，检查频率参见过程表3.0 | | | | | |
| 2.7 | Is furnace loading specified, documented and controlled? | Furnace loading parameters shall be specified, documented, and controlled. Examples include feed rate, belt speed, number of parts per fixture, and load weight. Refer to Process Tables, Section 3.0, for frequency of checks. | | | | | |
| 2.8 | ·操作者是否得到有关当设备出现紧急情况（包括动力中断时）如何进行材料处理、围堵措施和隔离产品的培训？ | ·非计划或紧急情况停工在很大程度上来引起不恰当过程的风险
·操作者应得到有关当设备出现紧急情况（包括动力中断时）如何进行材料处理、围堵措施和隔离产品的培训
·应形成培训文件，表明设备出现紧急情况或失效的潜在类型的作业指导书易于被设备操作者接受和理解，这类指导应规定所有与热处理过程有关的围堵措施，应覆盖整个热处理过程：装炉、奥氏体化、淬火和回火 | | | | | |
| 2.8 | Are operators trained in material handling, containment action and product segregation in the event of an equipment emergency including power failure? | Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment actions related to all elements of the heat-treating process, e.g., loading, austenitizing, quenching, tempering. | | | | | |
| 2.9 | 在热处理搬运、储存和包装过程中是否能充分保证产品的质量? | ·某些设备具有不兼容所有零件结构的搬动装置和其它移动组件
·如容器装载过度的操作也可能增加零件损坏的风险
·产品的搬运、储存和包装应充分保证产品的质量
·应针对防止零件损坏和其它质量风险，对热处理装炉系统、在线搬运和发运过程进行评审 | | | | | |
| 2.9 | Is the handling, storage and packaging adequate to preserve product quality? | Some equipment includes conveyors and other moving components that may not be able to handle all part configurations. Other practices such as stacking of overloaded containers can also increase the risk of part damage. Handling, storage, and packaging shall be adequate to preserve product quality. The heat treater’s furnace loading system, in-process handling, and shipping process shall be assessed for risk of part damage or other quality concerns. | | | | | |
| 2.10 | 工厂的清洁、内部管理、环境及工作条件是否有 益于质量改进？ | ·工厂的清洁、内部管理、环境及工作条件应有益于质量改进
·应评审这些条件对质量的影响
·应清楚地规定和执行内部管理制度和政策
·应对设施中有害于质量的条件进行评审如：零件散落在地上、淬火池周围有油、不适合的工厂照明及烟雾等 | | | | | |
| 2.10 | Are plant cleanliness, housekeeping, environmental, and working conditions conducive to quality improvements? | Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to quality improvements. The heat treater should evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for conditions that are detrimental to quality processing such as loose parts on floor, oil around quench tanks, inadequate plant lighting, smoke, etc. | | | | | |
| 2.11 | 零件是否避免了一些对随后热处理过程有害的污染物的影响？ | ·许多零件在热处理后要进行表面处理如电镀和涂装，零件应避免一些对随后过程有害的污染物的影响，有关处理前清洗和处理后清洗参数应该得到监控并记录，一旦粘上汕油、污染物或残余物是很难驱除的
·应评审化学供应商有关对清洗系统的建议
·在热处理之前避免铁锈、毛刺、碎屑、有害的润滑剂混合物、乳化切削油、防锈油、润滑剂等
·参见适用的过程表的要求和规范以确定其可接受性，有关清洁方法的检查频率见过程表5.0 | | | | | |
| 2.11 | Are parts free from contaminants that would be detrimental to the heat treatment of the product? | Many heat-treated parts are subjected to surface finish or appearance operations such as plating or coating after heat treatment. Parts shall be free from contaminants that are detrimental to subsequent processes or the product. Pre-wash (if applicable) and post-wash parameters shall be monitored and documented. Oils and other contaminants or residues can be difficult to remove once subjected to the heat treatment process. Review the chemical supplier’s recommendation for cleaning the system. Parts shall be free of rust, burrs, chips, detrimental amounts of drawing compound, cutting fluids, rust preventing oils, lubricants, etc., prior to heat treat.
Note: Refer to the appropriate heat treater's requirements and specifications to determine acceptability. Refer to Process Table, Section 5.0, for frequency of checking washer solutions. | | | | | |
| 2.12 | 淬火系统是否得到监视、记录，并得到控制？ | ·淬火系统应得到监视、记录，并得到控制，如温度、搅拌、等级、浓度（适用时）、淬火时间或悬浮物，以达到规范要求，检查频率详见过程表3.0和5.0
·由计算机监控的设备，需要警报和警报日志，并满足确认要求
·对于采用整体淬火的热处理炉需要有淬火延迟（Quench Delay)的范围和警报
·针对淬火和回火的零部件应进行具体规定回火延迟（Temper Delay)时间，如渗碳、碳氮共渗、中性淬火固溶处理和时效等 | | | | | |
| 2.12 | Is the quenching system monitored, documented, and controlled? | The quenching system shall be monitored, documented, and controlled. The temperature, agitation, level, concentration (if applicable), time in the quenchant, and additions shall be controlled to the heat treater's specifications. Refer to Process Tables, Sections 3.0 and 5.0, for frequency of checks. Computer-monitoring equipment, with alarms and alarm logs, satisfy the verification requirement. Quench delay tolerance and alarm is required for furnaces with integral quench tanks. Temper delay time shall be specified by the heat treater for parts that are quenched and tempered, e.g., carburizing, carbonitriding, neutral hardening, solution treating and aging. | | | | | |
| 2.13 | 适用时，是否对可溶性的防锈油或其它防锈剂进行监视和控制？ | ·零件在热处理后经常需要浸泡或喷涂一些防锈溶液
·适用时，应对可溶性的防锈油或其它防锈剂进行监视和控制
·必须保持这些溶液的特性在规定的公差范围内，检查频率详见过程表5.0 | | | | | |
| 2.13 | Is soluble oil or other rust preventive monitored and controlled if applicable? | Parts are often dipped in or sprayed with rust preventive solutions immediately after the heat treating process. Soluble oil solutions or other rust preventive solutions shall be monitored and controlled, if applicable. The heat treater shall have and maintain documented tolerances for the solutions. Refer to Process Tables, Section 5.0, for frequency of checks. | | | | | |
| 2.14 | ·按过程表规定的频率要求进行过程控制参数的监控？ | ·按过程表规定的频率要求进行过程控制参数的监控
·带有警报和警报日志的计算机监控设备需要满足确认要求
·需指定专人通过如初始纸带记录和数据日志来核实这些过程参数
·按1.9节中的要求进行管理评审是必须的 | | | | | |
| 2.14 | Are process control parameters monitored per frequencies specified in Process Tables? | Process control parameters shall be monitored per frequencies specified in Process Tables. Refer to Process Tables, Section 3.0. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log. Management review is required per Question 1.9. | | | | | |
| 2.15 | 是否按过程表规定的规范及频率要求完成过程/最终的检验/试验？ | ·按过程表规定的规范及频率要求进行过程/最终的检验/试验，详见过程表4.0 | | | | | |
| 2.15 | Are In-Process / Final Test Frequencies performed as specified in Process Tables? | In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables, Section 4.0. | | | | | |
| 2.16 | 产品试验设备是否得到验证？ | ·产品试验设备应得到验证
·试验设备必须针对每一个适用的顾客特殊标准或由ASTM,DIN,EN,ISO,JIS,NIST,SAE等一致认可的标准进行验证和校准
·验证和校准的结果必须经内部评审、批准并记录存档 | | | | | |
| 2.16 | Is product test equipment verified? | Product test equipment shall be verified. Test equipment shall be verified/calibrated per applicable customer-specific standard or per an applicable consensus standard such as those published by ASTM, DIN, EN, ISO, JIS, NIST, SAE etc. Verification/calibration results shall be internally reviewed, approved, and documented. Refer to Process Tables, Section 1.0, for frequency of checks. | | | | | |
| | | | | | | |
Section 3 - Equipment 设备 |
| 3.1 | 热处理炉，气氛发生器和淬火系统配备有适当的过程控制装置吗？ | ·热处理炉，气氛发生器和淬火系统应配备有适当的过程控制装置，包括温度计、碳势或露点器、气体流量计、淬火监控系统包括搅拌器、温度控制器和淬火油分析仪，具体清单详见适用的过程表1.0 | | | | | |
| 3.1 | Do furnaces, generators, and quench systems have proper process control equipment? | The heat-treat furnaces, generators, and quench systems shall have proper process controls and related equipment. Examples include temperature, carbon potential/dew point, gas flows, quench montoring system including agitation, temperature control and quenching oil analysis, etc. as listed in the applicable Process Tables, Section 1.0. | | | | | |
| 3.2 | ·这些装置是否得到校准或验证、是否过期或还在使用期内？ | ·按规定的时间间隔进行校准/验证，详见适用的过程表1.0和2.0 | | | | | |
| 3.2 | Are process equipment calibrations and/or verification certified, posted, and current? | The calibration and certification of the process equipment shall be checked at regular specified intervals. Refer to the applicable Process Tables, Sections 1.0 and 2.0, for equipment calibration or certification time tables. | | | | | |
| 3.3 | ·热电偶及保护套是否按照此过程表要求进行检查和更换？ | ·热电偶和保护管应依据预防性维护计划进行定期检查和更换，详见适用的过程表2.0 | | | | | |
| 3.3 | Are thermocouples & protection tubes checked or replaced per Process Tables? | The thermocouples and protection tubes shall be checked or replaced in compliance to a preventive maintenance schedule. Refer to the applicable Process Tables, Section 2.0. | | | | | |
| 3.4 | 温度均匀性温度是否按照该过程表要求进行测试？ | ·按适用的过程表2.0的要求测量温度的均匀性
·低于AMS2750允许的频次是不允许的
·某些热处理炉的设计（如旋转炉）排除了这一点要求
·当温度均匀性研究不可能时，可以进行产品的研究 | | | | | |
| 3.4 | Are temperature uniformity surveys performed per requirements in Process Tables? | Temperature uniformity surveys shall be conducted per the requirements in the applicable Process Tables, Section 2.0. The frequency reductions allowed in AMS 2750 are not allowed under this document. Certain furnace designs, e.g., rotary retorts preclude direct temperature profiles. Indirect product studies are acceptable for furnaces where temperature uniformity studies are not possible. | | | | | |
| 3.5 | 热处理炉的控制热电偶与设置温度之差是否处于该过程表的要求之内？ | ·按适用的过程表2.0的极限要求控制炉内热电偶与设定值的变差
·该要求不适用于多区连续炉的第一区 | | | | | |
| 3.5 | Is the variation of the furnace controlled thermocouple from set point within the requirements in the Process Table? | The variation between the furnace-control thermocouple and the set point temperature shall be within the limits defined in the applicable Process Tables, Section 2.0. This does not apply to the first zone of a multi-zone continuous furnace. | | | | | |
| 3.6 | 是否每季度（一年四次）和任何修理/重置后，对过程及设备的警报器进行检查测试？ | ·应具有热处理过程和设备警报器清单
·至少每季度（一年四次）和在任何修理/重置后，对过程及设备的警报器进行测试，应保持检查测试的记录 | | | | | |
| 3.6 | Are the process & equipment alarm checks being tested quarterly or after any repair or rebuild? | The heat treater shall have a list of heat treat process and equipment alarms. These alarms shall be independently tested quarterly at a minimum, and after any repair or rebuild. These checks shall be documented. | | | | | |
| 3.7 | 气氛发生器、炉内气氛和碳势/露点是否得到连续的监视和自动控制，并形成记录？ | ·发生器、炉内气氛和碳势/露点应得到连续的监视和自动控制，并形成记录，详见适用的过程表1的1.0和3.0
·对渗碳/碳氮共渗/中性淬火，其碳势或露点的自动控制对所有的发生器和气氛炉均是必要的，除搅拌炉及摇摆炉外，这些要求针对渗碳、碳氮共渗和中性淬火是明确的
·如没有使用发生器，应对所提供的气体流量进行监视和控制
·审核员应按照客户要求、热处理控制计划及内部程序确认气氛控制系统的有效性、这些气氛控制系统应该维护气氛露点，碳势设置点在控制计划或内部程序规定的参数范围之内
·还需要有一个碳势/露点检查结果的备份方法，如露点仪、电阻丝，气体分析仪、薄片、碳棒等
·自动、连续气氛控制系统由传感器（如氧探针）或在线红外气氛分析仪on-line Infrared (IR)组成
·验证频率详见过程表1的3.0 | | | | | |
| 3.7 | Are generators and furnace atmospheres continuously monitored, automatically controlled, and documented? | Generator and furnace atmosphere carbon potential/dew point shall be continuously monitored, automatically controlled, and documented. This requirement is specific to Process Table 1, Sections 1.0 and 3.0, for carburizing, carbontiriding, and neutral hardening. Continuous monitoring and automatic control of the carbon potential/dew point is required for all generators and atmosphere furnaces except rotary retort and shaker furnaces that preclude in situ control and monitoring. This requirement is specific to carburizing, carbonitriding, and neutral hardening. If generators are not used, the flow rates of the supplied atmosphere gases shall be monitored and controlled. The assessor shall verify the effectiveness of the atmosphere control system per customer requirement, the heat treater’s control plan, and internal procedures. The atmosphere control system shall maintain the atmosphere dew point/carbon potential set point within the parameters specified in the control plan or internal procedures. The heat treater shall have a back-up method of checking the carbon potential/dew point. Examples are dew point, electrical wire resistance,
gas analysis, shim stock, carbon bar, etc. The automatic and
continuous atmosphere control system shall consist of sensors such
as oxygen probes or on-line Infrared (IR) gas analysis. See Process
Table 1, Sect. 3.0 for verification frequencies. | | | | | |
| 3.8 | 当气氛监控备选系统的备份读数与原来的控制方法确定的极限值不一致或不相关时，是否重新确定？ | ·如果气氛验证检查的备份读数与原来的控制方法确定的极限值不一致或不相关时，热处理商应解决超差的问题
·气氛监控备选系统的读数和自动控制气氛露点/碳势的读数应保证规定在控制计划或内部程序所规定的范围之内
·碳势/露点的备份读数可以用以下一种或多种方法确定：
·碳棒或碳片 ·薄片 ·三气分析仪Three Gas Analyzer ·露点 ·电热线圈电阻
·这些范围大小随着所规定的热处理过程和所使用的设备不同而不同
·热处理商应用适当的方法调整、纠正、和重新建立/确定实际的气氛碳势/露点读数和原有的控制和备份的气氛读数之间的差异，两种读数间建立联系的许可范围应写入控制计划或内部程序 | | | | | |
| 3.8 | When the back-up verification check of the atmosphere does not agree or correlate within pre-established limits with the primary control method (carbon potential/dew point reading), is correlation of the carbon-bearing atmosphere to the primary control method re-established?
| This issue is specific to Process Table 1, carburizing, carbonitriding, and neutral hardening.
When the back-up verification check of the atmosphere does not agree or correlate within pre-established limits with the primary control method (carbon potential/dew point reading), the heat treater shall resolve the out-of-limit discrepancy. The back-up atmosphere monitoring system reading and the automatically controlled atmosphere dew point/carbon potential reading shall be maintained within the correlation limits specified in the control plan or internal procedures. These range tolerances vary with the specific heat treat process and the equipment used.
The heat treater shall make appropriate technical adjustments and corrections and then re-establish/demonstrate the correlation of the actual atmosphere carbon potential/dew point reading to the primary control and back-up atmosphere reading. The range tolerances for correlation between the two readings shall be in the control plan or internal procedures. The back-up carbon potential/dew point reading shall be established using one or more of the following methods:
• Carbon bar or slug
• Shim stock
• 3-gas analyzer
• Dew point
• Hot wire resistance | | | | | |
| 3.9 | 是否所有的氨管线都装有快速断开或三阀防故障安全排气系统？ | ·所有连接热处理炉的氨管道应装备快速断开装置或者三阀防故障安全排气系统
·定位阀即使当它们都关闭时，也能让氨气泄漏，因为在热处理过程中，这些氨气是不需要的和有害的，针对不需要氨气氛的热处理过程该要求不是必须的
·当碳氨共渗（或者它使用氨气的热处理过程）之或者其它热处理操作不规定使用氨气之前，氨气线可以分离
·三阀防故障安全排气系统是可行的，有关三阀自动防故障系统（Three Valve Fail-Safe Vent)详见附录B述语中的定义
·当无氨气氛过程需要将氨气线分离时，氨气管道断开应作出文件规定 | | | | | |
| 3.9 | Are all ammonia lines equipped with quick disconnects or a three valve fail safe vent system? | All ammonia lines to furnaces shall be equipped with quick disconnects or a three-valve fail-safe vent system. Normal valves may allow ammonia to leak through even when they are closed. This can be undesirable and detrimental in heat treat processes not specifying/requiring ammonia.
• A quick disconnect shall be present in any ammonia line going to a furnace. This line shall be disconnected after carbonitriding (or any other process using ammonia) before another heat treating operation not specifying/using ammonia begins.
• An alternative three-valve ammonia "fail-safe" vent system is permitted. See the definition “Three Valve Fail-Safe Vent” and diagram in the glossary.
• Documentation shall show when ammonia lines are disconnected for non-ammonia bearing atmosphere processes. | | | | | |
| 3.10 | 针对扣件和小型零部件，在处理产品之前（完成需要氨气的产品处理后）是否进行了至少3个小时的氧气燃尽？（Oxidizing Rum-Out) | ·该条款适用于扣件和小的金属零件，要求热处理商在处理产品之前至少应完成三小时的氧化烧烬过程，因为对于不特别规定或要求氨水的热处理过程，氨水是不需要的，值班日记或数据记录器或其它记录应记录实际的氧化烧烬时间，因为足够的时间能在不需要氨气的产品处理之前有效驱除表面的氨水 | | | | | |
| 3.10 | For fasteners and small metal parts, is a minimum of 3 hours allocated for an oxidizing burn-out prior to processing product not requiring ammonia? | This is applicable to fasteners and small metal parts. The heat treater shall perform a minimum 3 hours oxidizing burn-out prior to processing product not requiring ammonia as an addition. Ammonia pick-up can be undesirable in parts and heat treat processes not specifying/requiring ammonia as an addition. Log book, data logger, or other records shall document the actual oxidizing burn-out time and that sufficient time has been allocated to remove ammonia from the furnace prior to processing parts in heat treat processes not specifying ammonia. | | | | | |
| 3.11 | 所有的气氛炉和发生器是否有气体流量范围或流量计? | ·所有的气氛炉和发生器应有气体流量范围或流量计？
·均应按预防性维护计划进行定期保养和维护
·应文件规定清洁和可能的重新组装的要求 | | | | | |
| 3.11 | Do all atmosphere furnaces and generators have flow scopes or flow meters for all gases? | All atmosphere furnaces and generators (output trim/adjustment gas) shall have flow scopes or flow meters for all gases. Flow scopes and meters shall be periodically serviced per the heat treater's preventive maintenance program. Cleaning and proper re-assembly procedures shall be documented. | | | | | |
| 3.12 | 对于线形坚固件，是否所有的连续炉都装有玻璃观察孔和并在淬火炉的未端装有高温红外测温仪？ | ·应在连续炉的出口端安装气体红外线高温仪，以监视低于设定温度的零件，其温度报警应设在28℃（50F）之内，监控结果应该形成纸带记录或进行连续的数据记录
·红外测试仪应至少每年进行校准和鉴定
·所有的观察孔必须按预防性维护计划进行清洗 | | | | | |
| 3.12 | For threaded fasteners, are all continuous belt furnaces equipped with sight glass inspection ports and infrared pyrometers at discharge end of the hardening furnace? | Infrared temperature pyrometers are required at the exit end of continuous belt furnaces running threaded fasteners to monitor for under temperature parts. The temperature alarm shall be within 28oC (50oF) of the furnace set point temperature. Results shall be strip charted or continuously data logged. Infrared (IR) units shall be calibrated annually at a minimum and certified. All sight glasses shall be cleaned per the preventive maintenance schedule. | | | | | |
| 3.13 | 奥氏体盐浴的化学特性是否得到监控？ | ·该条款适用于铁酸盐碳氮共渗、奥氏体回火和中性盐淬
·应每天监控奥氏体盐浴室的盐的化学性和零件的脱碳情况，监控的频率详见适用的过程表3.0 | | | | | |
| 3.13 | Is salt chemistry in the austenitiz ing salt bath monitored? | Applicable to ferritic-nitrocarburizing, austempering, and neutral hardening in salt.
The heat treater shall check the salt chemistry in the austenitizing salt bath, or part decarburization, daily. Refer to the applicable Process Tables, Section 3.0, for frequency of checks. | | | | | |
| 3.14 | 是否对淬火介质进行分析？ | ·必须周期性地进行淬火介质（Quenching Medium）的特性分析，如冷却曲线、含水量、盐的浓度，详见适用的过程表5.0
·淬火介质特性值的允许范围应由热处理淬火介质的供应商或热处理供应商进行规定
·热处理供应商应针对其符合性进行审核并记录 | | | | | |
| 3.14 | Is the quenching medium analyzed? | The heat treater shall periodically have the quenching medium analyzed for specific quenching characteristics, e.g., cooling curve, water content, salt concentration, as specified in the applicable Process Tables, Section 5.0.
• The quench media characteristic tolerances shall be specified by the quench medium supplier or the heat treater.
• Analysis shall be reviewed for conformance by the heat treater. This review shall be documented. | | | | | |
FOR INDUCTION HEAT TREATING感应热处理 |
| 3.15 | 是否对每一零件的位置进行控制？ | ·如使用接近开关/光学传感器、机械探测器等方法探测每一零件的位置 | | | | | |
| 3.15 | Is the positioning of each part being controlled? | A method to detect proper part position, such as the use of proximity switches, optical sensors, mechanical probes, etc., is required for each part. | | | | | |
| 3.16 | 是否对每个零件的能量进行控制？ | ·必须控制每一零件的能量或功率
·针对每台设备的信号监视器是首选的，该监视器能给出能量单位（如电压伏特，功率千瓦等）VS.时间和距离（针对扫描系统）
·一个能量监视器或等效设备应获得设计确认后方可接受 | | | | | |
| 3.16 | Does the heat treater control the energy or power for each part? | The heat treater shall control the energy or power for each part.
• A signature monitor for each machine is preferred. A signature monitor gives the energy unit (voltage, kilowatt, etc.) vs. time or distance (for scanning systems).
• An energy monitor or equivalent is acceptable if approved by the design authority. | | | | | |
| 3.17 | 供应商是否建立一个感应圈的管理系统？感应圈应涉及到加热圈和淬火压力通风系统 | 供应商应建立一个感应圈的管理系统，感应圈应涉及到加热圈和淬火压力通风系统：
·针对每一种零件的备份线圈应在现场可获得
·线圈应满足批准时的初始设计要求
·线圈设计发生变更，必须获得顾客的工程变更批准 | | | | | |
| 3.17 | Does the supplier have a coil management system? | The heat treater shall have a coil management system. Coil refers to the heating coil and the quench plenum.
• Spare coils for each part shall be available on-site.
• Coils shall conform to the approved original design.
• Engineering change approval from the customer is required whenever the coil design is changed. | | | | | |
| 3.18 | 淬火系统是否自动、机械化？ | ·淬火系统应该是一个自动化操作过程，除非有资格的设计人员（Design authority)的批准，否则人工淬火是不允许的
·淬火必须自动地进行并得到控制 | | | | | |
| 3.18 | Is quench system automatic? | The quench system shall be an automatic operation. No manual quenching is allowed unless specifically approved by the design authority. Quenching shall be automatically initiated and controlled. | | | | | |
| 3.19 | 是否每批零件都做首件作业准备验证？ | ·热处理商应该完成每批零件的首件作业准备验证（Firsr piece set-up) | | | | | |
| 3.19 | Does each lot of parts have first piece set-up? | The heat treater shall perform first piece set-up for each lot of parts | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
| | | | | | | |
发表于 2014-12-28 18:58:34
|Archiver|手机版|小黑屋|热处理之家
( 湘ICP备16021836号 )公安部备案号：43010302000896
发表于 2014-12-28 20:35:52
发表于 2015-6-26 17:15:28
