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CQI-23SpecialProcesses:MoldingSystemAssessmentVersion1,3/2014Name:Title:Phone:Name:Company:Phone:ProcessTableBProcessTableCProcessTableDAuditors/Assessors:Email:NumberofProcessTableItemsnotmeetingMinimumRequirements:NumberofNotSatisfactoryFindings:NumberofNeedsImmediateActionFindings:NumberofFailFindingsintheJobAudit(s):PersonnelContacted:Email:DateofAssessment:DateofPreviousAssessment:CurrentQualityCertification(s):DateofRe-assessment(ifnecessary):EquipmentExtrusionProcessTableECompressionMoldingProcessTableFSpecialProcess:MoldingSystemAssessmentNumberofMoldingEmployeesatthisFacility:FaxNumber:Address:FacilityName:Type(s)ofMoldingProcessesatthisFacility:ProcessTableAPhoneNumber:InjectionMoldingCaptiveMolder(Y/N):CommercialMolder(Y/N):PartInspection&TestingProcessTableGProcessTableHBlowMoldingVacuumFormingTransferMoldingCQI-23SpecialProcesses:MoldingSystemAssessmentVersion1,3/2014QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateAction1.1Isthereadedicatedandqualifiedmoldingprofessionalon-site?Toensurereadilyavailableexpertise,thereshallbeadedicatedandqualifiedmoldingpersononthesite.Thisindividualshallbeafull-timeemployeeandthepositionshallbereflectedintheorganizationchart.Ajobdescriptionshallexistidentifyingthequalificationsforthepositionincludingchemicalandmoldingknowledge.Thequalificationsshallincludeaminimumof5yearsexperienceinmoldingoperationoracombinationofaminimumof5yearsofformaltechnicaleducationandmoldingexperience.1.2Doesthemolderperformadvancedqualityplanning?Themoldershallincorporateadocumentedadvancedqualityplanningprocedure.Afeasibilitystudyshallbeperformedandinternallyapprovedforeachnewpartorprocess.Similarpartscanbegroupedintopartfamiliesforthiseffortasdefinedbythemolder.Afterthepartapprovalprocessisapprovedbythecustomer,noprocesschangesareallowedunlessapprovedbythecustomer.Themoldershallcontactthecustomerwhenclarificationofprocesschangesisrequired.Thisclarificationofprocesschangesshallbedocumented.SpecialProcess:MoldingSystemAssessment(GeneralFacilityOverview)Section1-ManagementResponsibilityandQualityPlanningAssessmentSection1-2,2of48CQI-23SpecialProcesses:MoldingSystemAssessmentVersion1,3/2014QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionSpecialProcess:MoldingSystemAssessment(GeneralFacilityOverview)Assessment1.3Arethemolder'sFMEA'suptodateandreflectingcurrentprocessing?ThemoldershallincorporatetheuseofadocumentedFailureModeandEffectsAnalysis(FMEA)procedureandensuretheFMEAsareupdatedtoreflectcurrentpartqualitystatus.TheFMEAshallbewrittenforeachpartorpartfamilyortheymaybeprocess-specificandwrittenforeachprocess.Inanycase,theyshalladdressallprocessstepsfrompartreceipttopartshipmentandallkeymoldingprocessparametersasdefinedbythemolder.Across-functionalteamshallbeusedinthedevelopmentoftheFMEA.Allspecialcharacteristics,asdefinedbythemolderanditscustomers,shallbeidentified,defined,andaddressedintheFMEA.1.4AremoldingprocessControlPlansuptodateandreflectingcurrentprocessing?ThemoldershallincorporatetheuseofadocumentedControlPlanprocedureandensuretheControlPlansareupdatedtoreflectcurrentcontrols.TheControlPlansshallbewrittenforeachpartorpartfamilyortheymaybeprocess-specificandwrittenforeachprocess.Inanycase,theyshalladdressallprocessstepsfrompartreceipttopartshipmentandidentifyallequipmentusedandallkeymoldingprocessparametersasdefinedbythemolder.Across-functionalteam,includingaproductionoperator,shallbeusedinthedevelopmentofControlPlans,whichshallbeconsistentwithallassociateddocumentationsuchasworkinstructions,shoptravelers,andFMEAs.Allspecialcharacteristics,asdefinedbythemolderanditscustomers,shallbeidentified,defined,andaddressedintheControlPlans.SamplesizesandfrequenciesforevaluationofprocessandproductcharacteristicsshallalsobeaddressedconsistentwiththeminimumrequirementslistedintheProcessTables.Section1-2,3of48CQI-23SpecialProcesses:MoldingSystemAssessmentVersion1,3/2014QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionSpecialProcess:MoldingSystemAssessment(GeneralFacilityOverview)Assessment1.5Areallmoldingrelatedandreferencedspecificationscurrentandavailable?Forexample:SAE,AIAG,ASTM,GeneralMotors,Ford,andChrysler.Toensureallcustomerrequirementsarebothunderstoodandsatisfied,themoldershallhaveallrelatedmoldingandcustomerreferencedstandardsandspecificationsavailableforuseandamethodtoensurethattheyarecurrent.Suchstandardsandspecificationsinclude,butarenotlimitedto,thoserelevantdocumentspublishedbySAE,AIAG,ASTM,GeneralMotors,Ford,andChrysler.Themoldershallhaveaprocesstoensurethetimelyreview,distribution,andimplementationofallcustomerandindustryengineeringstandardsandspecificationsandchangesbasedoncustomer-requiredschedule.Thisprocessshallbeexecutedassoonaspossibleandshallnotexceedtwoweeks.Themoldershalldocumentthisprocessofreviewandimplementation,anditshalladdresshowcustomerandindustrydocumentsareobtained,howtheyarema