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Special Process: Welding System Assessment
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
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, EDI/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 a consensus of those substantially concerned with its scope and provisions. An AIAG publication is intended as a guide to aid the manufacturer, the consumer and the general public. The existence of an AIAG publication does not in any respect preclude anyone from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the publication.
CAUTIONARY NOTICE
AIAG publications are subject to periodic review and users are cautioned to obtain the latest editions.
MAINTENANCE PROCEDURE
Recognizing that this AIAG publication may not cover all circumstances, AIAG has established a maintenance procedure. Please refer to the Maintenance Request Form at the back of this document to submit a request.
Published by: Automotive Industry Action Group
26200 Lahser Road, Suite 200 Southfield, Michigan 48033
Phone: (248) 358-3570 • Fax: (248) 358-3253
APPROVAL STATUS
The AIAG Quality Steering Committee and designated stakeholders approved this document for publication in March 2010.
AIAG COPYRIGHT AND TRADEMARK NOTICE:
© 2010 Automotive Industry Action Group, except that copyright is not claimed as to any part of an original work prepared by a U.S. or state government officer or employee as part of the person’s official duties. Except as noted above, all rights are reserved by AIAG and no part of these materials may be reproduced, reprinted, stored in a retrieval system, or transmitted, in any form or by any means, electronic, photocopying, recording, or otherwise, without the prior written permission of Automotive Industry Action Group. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group. Automotive Industry Action Group makes no claim to any trademark of a third party. Trademarks of third parties included in these materials are the property of their respective owners. © 2010 Automotive Industry Action Group ISBN 978 1 60534 208 5
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
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.
ACKNOWLEDGEMENTS
Core Members:
Joseph Beckham Chrysler Group LLC
Gilbert Chrostowski TRW Automotive
Virender Choudhri Delphi Corporation
Thomas Lopiccolo General Motors Company
Neal McMichael Ford Motor Company
Carl Occhialini The Lincoln Electric Company
Veronica Sebald Toyota Motor Engineering & Manufacturing, North America
Ryan Turnwald Honda of America Manufacturing, Inc.
Dave Willig Nexteer Automotive
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TABLE OF CONTENTS ABOUT AIAG .............................................................................................................................................................1
FOREWORD ...............................................................................................................................................................3
ACKNOWLEDGEMENTS ........................................................................................................................................3
TABLE OF CONTENTS ............................................................................................................................................4
INTRODUCTION .......................................................................................................................................................5
GENERAL ...................................................................................................................................................................5 PROCESS APPROACH ..................................................................................................................................................5 WELDING SYSTEM ASSESSMENT GOALS....................................................................................................................5 ASSESSMENT PROCESS...............................................................................................................................................5 ASSESSOR QUALIFICATIONS ......................................................................................................................................6 OTHER REQUIREMENTS..............................................................................................................................................6
1 SCOPE.......................................................................................................................................................................7
1.1 GENERAL .............................................................................................................................................................7 1.2 APPLICATION .......................................................................................................................................................7 1.3 REFERENCE ..........................................................................................................................................................8
2 THE WELDING SYSTEM ASSESSMENT PROCEDURE ................................................................................9
3 SPECIAL PROCESS: WELDING ASSESSMENT ............................................................................................10
APPENDIX A – PROCESS TABLES......................................................................................................................31
GLOSSARY ...............................................................................................................................................................49
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
INTRODUCTION
General The work of preparing CQI-15: Special Process: Welding System Assessment (WSA) was carried out through the AIAG Welding Work Group. These welding requirements are complementary to customer and product standards.
The WSA 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 WSA can also be used between an organization and its suppliers.
In the WSA, 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 WSA supports the automotive process approach as described in ISO/TS 16949.
Welding System Assessment Goals The goal of the WSA is the development of a welding management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain.
The WSA, coupled with an internationally recognized quality management system and applicable customer-specific requirements, defines the fundamental requirements for welding management systems.
The WSA is intended to provide a common approach to a welding management system for automotive production and service part organizations.
Assessment Process Ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to re-examine the continuing compliance with the WSA. Each assessment shall include a review of the organization’s systems using the WSA. Successive Job Audits (Section 6.0 of this document) shall sample parts from different automotive component manufacturers that require compliance to the WSA document.
The assessment shall use the process approach to auditing as identified by the requirements of ISO/TS 16949. Prop
erty o
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otors
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Assessor Qualifications Assessor(s) shall have the following specific experience to conduct the WELDING SYSTEM ASSESSMENT:
1. Be an experienced quality management system (QMS) internal auditor (for example, latest edition of ISO/TS 16949, ISO 9001)
2. Assessor shall possess welding knowledge. Evidence shall include a minimum of 5 years experience in welding or a combination of formal education in welding and welding 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 WSA, 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.
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
1 SCOPE
1.1 General This document specifies process requirements for an organization or its suppliers performing applicable welding, 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 Welding 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 WSA are generic and are intended to be applicable to all organizations performing the welding operations addressed in this document, regardless of type, size, and product.
Note: Four Process Tables have been developed and the appropriate table(s) is to be referenced during the assessment. The Process Tables are specific to welding processes as noted below:
Process Table A - Arc Welding
Arc Stud/Fastener Welding
Flux-Cored Arc Welding
Gas Metal Arc welding
Submerged Arc Welding
Shielded Metal Arc Welding
Plasma Arc Welding
Gas Tungsten Arc Welding
Gas Metal Arc Braze Welding
Process Table B - Resistance Welding
Resistance Spot Welding
Projection Welding
Resistance Seam Welding
High-Frequency Seam Welding
Induction Seam Welding
Mash Seam Welding
Flash Welding
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Process Table C - Laser Welding
Nd YAG CO2 DIODE
Wire Fed
Process Table D - Solid State Welding
Inertia Friction Welding
Direct Drive Friction Welding
Friction Stir Welding
Flash Butt Welding
Resistance Butt Welding
Ultrasonic Welding
These Process Tables contain requirements for:
1. Management Responsibility & Quality Planning
2. Floor and Material Handling Responsibility
3. Equipment / Facilities/Controls
4. Tooling/Fixturing
5. Process Controls and Confirmation
6. Essential Variables
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 WSA form will notify the assessor when to refer to the Process Tables.
1.3 Reference The following standards are used as reference material. There are other reference materials that contain more information, however, the list is not meant to be inclusive. The applicability is limited to the subject matter referenced.
Standard Number Title Standard’s Organization
ANSI Z 49.1 Safety in Welding and Cutting ANSI - www.ansi.org
AWS A3.0 Standard Welding Terms and Definitions
www.aws.org
AWS C7.2 Recommended Practices for Laser Beam and Welding
www.aws.org
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
2 THE WELDING SYSTEM ASSESSMENT PROCEDURE
1. Obtain current copy of CQI-15 Special Process: Welding System Assessment, from AIAG.
2. Identify all welding processes to which CQI-15 Special Process: Welding System Assessment, applies (see CQI-15, 1.2). Record these processes on the WSA.
3. Complete the WSA, determining the level of compliance. A minimum of one job audit (Section 6) 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.
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3 SPECIAL PROCESS: WELDING ASSESSMENT
Cover Sheet................................................................................................................................................. 15
Section 1-5 .................................................................................................................................................. 18
Section 1: Management Responsibility & Quality Planning ..................................................................... 18
Section 2: Floor and Material Handling Responsibility............................................................................. 24
Section 3: Equipment ................................................................................................................................. 26
Section 4: Tooling/Fixturing...................................................................................................................... 27
Section 5: Process Controls and Confirmation .......................................................................................... 27
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Instructions for completing the Cover Sheet
1. 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 or different management system, then these locations shall be considered as separate facilities.
2. Address: The street address of the facility being assessed; P.O Box numbers may be given as additional information.
3. 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.
4. Fax Number: The fax number of the facility.
5. Number of Welding Employees at this Facility: The number of employees, salaried and hourly, associated with the welding operation at this facility.
6. Captive Weld Organization (Y/N): Enter “Y” if this facility welds components for their own company. Enter “N” if the company does not weld any components for their own company.
7. Commercial Weld Organization (Y/N): Enter “Y” if this facility welds components for companies other than their own company. Enter “N” if this facility does not weld any components for other companies.
8. 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, 2010
9. Date of Previous Assessment: List the date of the previous CQI-15 Special Process: Welding System Assessment of this facility.
10. Type(s) of Welding Processing at this Facility: Place a checkmark to designate all welding 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 Welding System Assessment.
11. Current Quality Certification(s): The weld organization shall list their current quality certifications, e.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.
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12. Date of Re-assessment (if necessary): If “Not Satisfactory” findings were observed from the original assessment, then the weld organization 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 – 5, 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 Satisfactory Findings” shall be modified as appropriate.
13. Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available, of the principal participants from the weld organization.
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” Findings: Enter the number of “Needs Immediate Action” findings observed during the assessment.
17. Number of “Fail” Findings in the Job Audit(s): Enter the number of “Fail” findings observed from the job audit.
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Process Table A - Arc Welding
Arc Stud/Fastener WeldingFlux Cored Arc WeldingGas Metal Arc Welding
Captive Weld Organization (Y/N) Submerged Arc Welding
Shielded Metal Arc Welding
Commercial Weld Organization Plasma Arc Welding
Gas Tungsten Arc Welding
Date of Assessment: Gas Metal Arc Braze Welding
Process Table B - Resistance Welding
Resistance Spot Welding
Date of Previous Assessment: Projection WeldingResistance Seam Welding
High-frequency Seam Welding
Induction Seam Welding
Mash Seam Welding
Flash Welding
Process Table C - Laser Welding
Nd YAG Welding
CO2 Welding
Diode Welding
Wire Fed
Process Table D - Solid State Welding
Inertia Friction WeldingDirect Drive Friction Welding
Friction Stir Welding
Flash Butt Welding
Resistance Butt Welding
Ultrasonic Welding
Personnel Contacted:
Name Title Phone
Auditors/Assessors
Name Company Phone
Number of "Needs Immediate Action" Findings
Number of "Fail" Findings in the Job Audit(s)
Number of "Not Satisfactory" Findings
Current Quality Certification(s)
Special Process: Welding System Assessment
Address:Facility Name:
Type(s) of Weld Processing at this Facility:
Number of Welding Employees at this Facility:
Phone Number:
Fax Number:
Date of Re-assessment (if necessary):
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Instructions for completing Sections 1 – 5
Sections 1 - 5 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/Facilities/Control
Section 4 – Tooling/Fixturing
Section 5 – Process Controls and Confirmation
The assessor shall assess the weld organization compliance to Sections 1 – 5 by comparing the evidence presented by the weld organization to the requirements listed in the “Requirements and Guidance” column.
NOTE 1: In the “Requirements and Guidance” column, the word “shall” indicates a 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 weld organization compliance to the specified section(s) in the Process Tables.
NOTE 3: If the question is not applicable to the weld organization, 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.
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Qu
es
tio
n
Nu
mb
er
Qu
es
tio
nR
eq
uir
em
en
ts a
nd
Gu
ida
nc
eO
bje
cti
ve
Ev
ide
nc
eN
/AS
ati
sfa
cto
ryN
ot
Sa
tis
fac
tory
Ne
ed
s I
mm
ed
iate
A
cti
on
1.1
Is t
he
re a
de
dic
ate
d a
nd
q
ua
lifie
d t
ech
nic
al w
eld
ing
p
ers
on
on
-site
?
To
en
sure
re
ad
ily a
vaila
ble
exp
ert
ise
, th
ere
sh
all
be
a
de
dic
ate
d a
nd
qu
alif
ied
we
ldin
g p
ers
on
on
site
. T
his
in
div
idu
al s
ha
ll b
e o
ne
of
the
fo
llow
ing
: D
eg
ree
d W
eld
ing
E
ng
ine
er,
or
eq
uiv
ale
nt
scie
nce
de
gre
e,
Ce
rtifi
ed
We
ldin
g
Insp
ect
or
fro
m a
pp
rove
d in
tern
atio
na
lly r
eco
gn
ize
d b
od
y,
or
pe
rso
n a
gre
ed
up
on
be
twe
en
cu
sto
me
r a
nd
su
pp
lier.
T
his
pe
rso
n s
ha
ll b
e a
fu
ll-tim
e e
mp
loye
e a
nd
th
e p
osi
tion
sh
all
be
re
flect
ed
in t
he
org
an
iza
tion
ch
art
. A
job
d
esc
rip
tion
sh
all
exi
st id
en
tifyi
ng
th
e q
ua
lific
atio
ns
for
the
p
osi
tion
incl
ud
ing
me
tallu
rgic
al a
nd
we
ldin
g k
no
wle
dg
e.
Th
e q
ua
lific
atio
ns
sha
ll in
clu
de
a m
inim
um
of
5 y
ea
rs
exp
eri
en
ce in
we
ldin
g o
pe
ratio
ns
or
a c
om
bin
atio
n o
f a
m
inim
um
of
5 y
ea
rs o
f fo
rma
l me
tallu
rgic
al e
du
catio
n a
nd
w
eld
ing
exp
eri
en
ce.
1.2
Is t
he
re a
re
spo
nsi
bili
ty m
atr
ix
to e
nsu
re t
ha
t a
ll ke
y m
an
ag
em
en
t a
nd
su
pe
rvis
ory
fu
nct
ion
s a
re p
erf
orm
ed
by
qu
alif
ied
pe
rso
nn
el?
Th
e o
rga
niz
atio
n s
ha
ll m
ain
tain
a r
esp
on
sib
ility
ma
trix
id
en
tifyi
ng
all
key
ma
na
ge
me
nt
an
d s
up
erv
iso
ry f
un
ctio
ns
an
d t
he
qu
alif
ied
pe
rso
nn
el w
ho
ma
y p
erf
orm
su
ch
fun
ctio
ns.
It
sha
ll id
en
tify
bo
th p
rim
ary
an
d s
eco
nd
ary
(b
ack
up
) p
ers
on
ne
l fo
r th
e k
ey
fun
ctio
ns
(as
de
fine
d b
y th
e o
rga
niz
atio
n).
Th
is m
atr
ix s
ha
ll b
e r
ea
dily
ava
ilab
le t
o
ma
na
ge
me
nt
an
d c
ust
om
er
at
all
time
s.
1.3
Do
yo
u u
se o
nly
qu
alif
ied
w
eld
ers
(p
ers
on
ne
l)?
Th
e o
rga
niz
atio
n s
ha
ll p
rovi
de
em
plo
yee
tra
inin
g f
or
all
we
ldin
g o
pe
ratio
ns
spe
cific
to
th
eir
job
fu
nct
ion
. A
ll w
eld
ing
em
plo
yee
s, in
clu
din
g b
ack
up
an
d t
em
po
rary
e
mp
loye
es,
sh
all
be
tra
ine
d.
Do
cum
en
ted
evi
de
nce
sh
all
be
ma
inta
ine
d s
ho
win
g t
he
em
plo
yee
s w
ere
tra
ine
d;
the
e
vid
en
ce s
ha
ll in
clu
de
an
ass
ess
me
nt
of
the
eff
ect
ive
ne
ss
of
the
tra
inin
g,
mu
st p
rove
kn
ow
led
ge
of
the
cu
sto
me
r's
spe
cific
re
qu
ire
me
nts
an
d in
tern
al s
tan
da
rds,
an
d w
he
re
ap
pro
pri
ate
, e
mp
loye
e c
ert
ifica
tion
, su
ch a
s fo
r a
ma
nu
al
we
lde
r.
Ma
na
ge
me
nt
an
d c
ust
om
er
sha
ll d
efin
e t
he
q
ua
lific
atio
n r
eq
uir
em
en
ts f
or
ea
ch f
un
ctio
n a
nd
on
go
ing
o
r fo
llow
-up
tra
inin
g s
ha
ll a
lso
be
ad
dre
sse
d.
1.4
Ho
w d
o y
ou
ma
inta
in w
eld
er
cert
ifica
tion
?
Re
qu
ire
d q
ua
lific
atio
n m
ain
ten
an
ce.
If
the
we
lde
r h
as
no
t w
eld
ed
in t
he
sp
eci
fic o
pe
ratio
n in
a 6
mo
nth
tim
e f
ram
e,
the
we
lde
r m
ust
be
re
qu
alif
ied
to
th
at
op
era
tion
. B
ase
d o
nth
e w
eld
er's
qu
alit
y p
erf
orm
an
ce,
it m
ust
be
est
ab
lish
ed
w
he
n r
etr
ain
ing
an
d r
eq
ua
lific
atio
n o
f th
e in
div
idu
al m
ust
b
e p
erf
orm
ed
.
1.5
Is s
et-
up
pra
ctic
e in
co
mp
lian
ce w
ith d
ocu
me
nte
d
wo
rk in
stru
ctio
ns?
Se
t-u
p v
eri
fica
tion
to
th
e p
roce
du
res
(as
exa
mp
le:
eq
uip
me
nt
sett
ing
s, c
lam
pin
g s
eq
ue
nce
, w
eld
se
qu
en
ce,
dir
ect
ion
of
tra
vel a
nd
oth
er
pro
cess
co
ntr
ols
) in
co
mp
lian
ce t
o d
ocu
me
nte
d w
ork
inst
ruct
ion
s.
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
Se
cti
on
1 -
Ma
na
ge
me
nt
Re
sp
on
sib
ilit
y &
Qu
ali
ty P
lan
nin
g
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Qu
esti
on
N
um
be
rQ
ue
sti
on
Re
qu
ire
me
nts
an
d G
uid
an
ce
Ob
jec
tiv
e E
vid
en
ce
N/A
Sa
tis
fac
tory
No
t S
ati
sfa
cto
ryN
ee
ds
Im
me
dia
te
Ac
tio
n
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
1.6
Do
es
the
we
ldin
g o
rga
niz
atio
n
pe
rfo
rm a
dva
nce
d q
ua
lity
pla
nn
ing
?
Th
e o
rga
niz
atio
n s
hal
l inc
orp
ora
te a
do
cum
en
ted
ad
vanc
e
qu
alit
y pl
ann
ing
pro
ced
ure
. A
fe
asib
ility
stu
dy
sha
ll b
e
pe
rfo
rme
d a
nd
inte
rna
lly a
pp
rove
d f
or
ea
ch p
art
. S
imila
r p
art
s ca
n b
e g
rou
pe
d in
to p
art
fa
mili
es
for
this
eff
ort
as
de
fine
d b
y th
e o
rgan
iza
tion
. A
fte
r th
e p
art
ap
pro
val
pro
cess
is a
ppr
ove
d b
y th
e c
ust
om
er,
no
pro
cess
ch
an
ge
s a
re a
llow
ed
un
less
app
rove
d b
y th
e c
ust
om
er.
T
he
w
eld
ing
org
an
iza
tion
sha
ll co
nta
ct t
he
cu
sto
me
r w
he
n
cla
rific
atio
n o
f p
roce
ss c
ha
ng
es
is r
eq
uire
d.
Th
is
cla
rific
atio
n o
f p
roce
ss c
han
ges
sha
ll b
e d
ocu
me
nted
.
1.7
Are
we
ldin
g F
ME
A's
up
to
date
an
d r
efle
ctin
g c
urr
ent
p
roce
ssin
g?
Th
e o
rga
niz
atio
n s
hal
l inc
orp
ora
te th
e u
se o
f a
d
ocu
me
nte
d F
ailu
re M
od
e a
nd
Eff
ects
An
aly
sis
(FM
EA
) p
roce
du
re a
nd
en
sure
th
e F
ME
A's
are
up
dat
ed
to
re
flect
cu
rre
nt p
art
qu
alit
y st
atu
s.T
he
FM
EA
sh
all
be
writ
ten
fo
r e
ach
pa
rt o
r p
art
fa
mily
or
the
y m
ay
be
pro
cess
-sp
eci
fic a
nd
writ
ten
fo
r e
ach
pro
cess
.In
an
y ca
se,
the
y sh
all
add
ress
all
pro
cess
ste
ps
fro
m p
art
re
ceip
t to
pa
rt s
hip
me
nt
and
all
key
we
ldin
g p
roce
ss
pa
ram
ete
rs a
s d
efin
ed
by
the
org
an
iza
tion
. A
cro
ss-
fun
ctio
na
l te
am
sh
all
be
use
d in
th
e d
eve
lop
men
t of
the
F
ME
A.
All
spe
cia
l ch
ara
cte
ristic
s, a
s de
fine
d b
y th
e
org
an
iza
tion
an
d it
s cu
sto
me
rs,
sha
ll b
e id
en
tifie
d,
de
fine
d,
an
d a
dd
ress
ed
in t
he
FM
EA
.
1.8
Are
we
ldin
g p
roce
ss c
on
trol
p
lan
s u
p to
da
te a
nd
refle
ctin
g
curr
en
t p
roce
ssin
g?
Th
e o
rga
niz
atio
n s
hal
l inc
orp
ora
te th
e u
se o
f a
d
ocu
me
nte
d C
on
tro
l Pla
n p
roce
du
re a
nd
en
sure
th
e
Co
ntr
ol P
lan
s ar
e u
pda
ted
to
re
flect
cu
rre
nt
con
tro
ls.
Th
e
Co
ntr
ol P
lan
s sh
all
be
writ
ten
fo
r e
ach
pa
rt o
r pa
rt f
am
ily
or
the
y m
ay
be
pro
cess
-sp
eci
fic a
nd
wri
tte
n f
or
ea
ch
pro
cess
. T
he
y sh
all
ad
dre
ss a
ll p
roce
ss s
tep
s fr
om p
art
re
ceip
t to
pa
rt s
hip
me
nt
and
ide
ntif
y a
ll e
qu
ipm
ent
use
d
an
d a
ll e
ssen
tial w
eld
ing
pro
cess
par
am
ete
rs a
s d
efin
ed
by
the
re
leva
nt i
nd
ivid
ua
l pro
cess
ta
ble
s o
r n
on-
ess
en
tial
as
ag
ree
d u
po
n b
etw
een
su
pp
lier
and
cu
sto
me
r. A
cro
ss-
fun
ctio
na
l te
am
, in
clu
din
g a
pro
du
ctio
n o
pe
rato
r, s
ha
ll b
e u
sed
in t
he
de
velo
pm
ent
of
Co
ntr
ol P
lan
s, w
hic
h s
hall
be
co
nsi
ste
nt
with
all
ass
oci
ate
d d
ocu
me
nta
tion
su
ch a
s w
ork
in
stru
ctio
ns,
sh
op t
rave
lers
, a
nd
FM
EA
's.
All
spe
cia
l ch
ara
cte
rist
ics,
as
de
fine
d b
y th
e o
rga
niz
atio
n a
nd
its
cust
om
ers
, sh
all
be
ide
ntif
ied
, d
efin
ed
, a
nd
ad
dre
sse
d in
th
e C
on
tro
l Pla
ns.
Sa
mpl
e s
ize
s a
nd
fre
qu
en
cie
s fo
r e
valu
atio
n o
f p
roce
ss a
nd p
rod
uct
ch
ara
cter
istic
s sh
all
als
o b
e a
dd
ress
ed
co
nsis
ten
t w
ith t
he
min
imu
m
req
uir
em
ents
list
ed
in t
he
Pro
cess
Ta
ble
s.
- 16 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 17 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Qu
es
tio
n
Nu
mb
er
Qu
es
tio
nR
eq
uir
em
en
ts a
nd
Gu
ida
nc
eO
bje
cti
ve
Ev
ide
nc
eN
/AS
ati
sfa
cto
ryN
ot
Sa
tis
fac
tory
Ne
ed
s I
mm
ed
iate
A
cti
on
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
1.9
Are
all
we
ldin
g r
ela
ted
an
d
refe
ren
ced
sp
eci
fica
tion
s cu
rre
nt
an
d a
vaila
ble
? F
or
exa
mp
le:
SA
E,
AIA
G,
AS
TM
, A
SM
E,
AW
S,
ISO
, G
en
era
l M
oto
rs,
Ho
nd
a,
Fo
rd,
To
yota
a
nd
Ch
rysl
er.
To
en
sure
all
cust
om
er
req
uir
em
en
ts a
re b
oth
un
de
rsto
od
a
nd
sa
tisfie
d,
the
org
an
iza
tion
sh
all
ha
ve a
ll sp
eci
fica
lly
rela
ted
we
ldin
g a
nd
cu
sto
me
r re
fere
nce
d s
tan
da
rds
an
d
spe
cific
atio
ns
ava
ilab
le f
or
use
an
d a
me
tho
d t
o e
nsu
re
tha
t th
ey
are
cu
rre
nt.
Su
ch s
tan
da
rds
an
d s
pe
cific
atio
ns
ma
y in
clu
de
, b
ut
are
no
t lim
ited
to
, th
ose
re
leva
nt
do
cum
en
ts p
ub
lish
ed
by
SA
E,
AIA
G,
AS
TM
, A
SM
E,
AW
S,
ISO
, G
en
era
l Mo
tors
, H
on
da
, F
ord
, T
oyo
ta,
an
d
Ch
rysl
er.
Th
e o
rga
niz
atio
n s
ha
ll h
ave
a p
roce
ss t
o e
nsu
re
the
tim
ely
re
vie
w,
dis
trib
utio
n,
an
d im
ple
me
nta
tion
of
all
cust
om
er
an
d in
du
stry
en
gin
ee
rin
g
sta
nd
ard
s/sp
eci
fica
tion
s a
nd
ch
an
ge
s b
ase
d o
n c
ust
om
er-
req
uir
ed
sch
ed
ule
. T
ime
ly r
evi
ew
sh
ou
ld b
e a
s so
on
as
po
ssib
le a
nd
sh
all
no
t e
xce
ed
tw
o w
ork
ing
we
eks
. T
he
o
rga
niz
atio
n s
ha
ll d
ocu
me
nt
this
pro
cess
of
revi
ew
an
d
imp
lem
en
tatio
n,
an
d it
sh
all
ad
dre
ss h
ow
cu
sto
me
r a
nd
in
du
stry
do
cum
en
ts a
re o
bta
ine
d,
ho
w t
he
y a
re m
ain
tain
ed
with
in t
he
org
an
iza
tion
, h
ow
th
e c
urr
en
t st
atu
s is
e
sta
blis
he
d,
an
d h
ow
th
e r
ele
van
t in
form
atio
n is
ca
sca
de
d
to t
he
sh
op
flo
or
with
in t
he
tw
o-w
ee
k p
eri
od
. T
he
o
rga
niz
atio
n s
ha
ll id
en
tify
wh
ois
re
spo
nsi
ble
fo
r p
erf
orm
ing
th
ese
ta
sks.
1.1
0Is
th
ere
a w
ritt
en
pro
cess
sp
eci
fica
tion
fo
r a
ll a
ctiv
e
pro
cess
es?
Th
e w
eld
ing
org
an
iza
tion
sh
all
ha
ve w
ritt
en
pro
cess
sp
eci
fica
tion
s fo
r a
ll a
ctiv
e p
roce
sse
s a
nd
re
pa
ir
pro
cess
es
wh
ich
ide
ntif
y a
ll st
ep
s o
f th
e p
roce
ss in
clu
din
g
rele
van
t o
pe
ratin
g p
ara
me
ters
. E
xam
ple
s o
f o
pe
ratin
g
pa
ram
ete
rs a
s d
efin
ed
by
the
re
leva
nt
pro
cess
ta
ble
s.
Su
ch p
ara
me
ters
sh
all
no
t o
nly
be
de
fine
d,
the
y sh
all
ha
veo
pe
ratin
g t
ole
ran
ces
as
de
fine
d b
y th
e o
rga
niz
atio
n in
o
rde
r to
ma
inta
in p
roce
ss c
on
tro
l.
Th
ese
pro
cess
sp
eci
fica
tion
s m
ay
take
th
e f
orm
of
wo
rk
inst
ruct
ion
s, jo
b c
ard
, se
t-u
p s
he
ets
, o
r o
the
r si
mila
r d
ocu
me
nts
.
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Qu
est
ion
N
um
be
rQ
ue
sti
on
Re
qu
ire
me
nts
an
d G
uid
an
ceO
bje
cti
ve
Ev
ide
nce
N/A
Sa
tis
fact
ory
No
t S
ati
sfa
cto
ryN
ee
ds
Im
me
dia
te
Ac
tio
n
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
Th
e o
rga
niz
atio
n s
ha
ll p
erf
orm
pro
du
ct c
ap
ab
ility
stu
die
s fo
r th
e in
itia
l va
lida
tion
of
ea
ch p
roce
ss,
aft
er
relo
catio
n o
f a
ny
pro
cess
eq
uip
me
nt,
an
d a
fter
a m
ajo
r pr
oce
ss c
ha
ng
e
of
an
y e
quip
me
nt o
r p
ara
me
ter.
Th
e o
rga
niz
atio
n a
nd
cu
sto
me
r sh
all
de
fine
wh
at
con
stitu
tes
a m
ajo
r p
roce
ss
cha
nge
. In
itia
l pro
du
ct c
ap
ab
ility
stu
die
s sh
all
be
co
ndu
cte
d f
or
all
wel
din
g p
roce
sse
s p
er
ea
ch p
roce
ss
pa
th d
efin
ed
in s
cop
e o
f w
ork
an
d in
acc
ord
anc
e w
ith
cust
om
er
requ
irem
ents
. In
the
ab
sen
ce o
f cu
sto
me
r re
qu
ire
men
ts,
the
org
an
iza
tion
sh
all
est
ab
lish
acc
ep
tab
le
ran
ge
s fo
r m
ea
sure
s o
f ca
pabi
lity.
An
act
ion
pla
n sh
all
exi
st t
o a
dd
ress
th
e s
tep
s to
be
fo
llow
ed
in c
ase
ca
pab
ility
in
dic
es
fall
ou
tsid
e cu
stom
er
req
uir
em
en
ts o
r e
sta
blis
he
d
ran
ge
s.
Ea
ch p
roce
ss p
ath
incl
ud
es
all
com
bin
atio
ns
of
equi
pm
en
t th
at
are
inte
gra
ted
in t
he
pe
rfo
rma
nce
of
a w
eld
ing
pro
cess
, e
.g.,
we
ld c
ell
with
A a
nd B
sid
e f
ixtu
re f
ee
din
g
an
oth
er
we
ld c
ell
with
A a
nd
B s
ide
fix
ture
or
mu
ltip
le
ma
chin
es.
Ca
pa
bilit
y st
udy
tech
niq
ue
s sh
all i
nclu
de
b
ou
nd
ary
sa
mp
le c
on
diti
on
s as
de
fine
d b
y th
e c
on
tro
l pla
n
tha
t a
re r
ob
ust
an
d m
ee
t a
ll cu
sto
me
r re
qu
ire
me
nts
. E
xam
ple
, a
ny
com
bin
atio
n o
f to
lera
nce
s a
s d
efin
ed
by
Pro
cess
Ta
ble
s.
1.1
2
Do
es
the
we
ldin
g o
rga
niz
atio
n
mo
nito
r a
nd
an
aly
ze d
ata
ove
r tim
e,
an
d r
ea
ct to
this
da
ta?
Th
e a
na
lysi
s o
f p
rod
uct
s o
r p
roce
sse
s o
ver
time
can
yie
ld
vita
l in
form
atio
n f
or
defe
ct p
reve
ntio
n e
ffo
rts.
Th
e
org
an
iza
tion
sha
ll h
ave
a s
yste
m t
o co
llect
, ana
lyze
, a
nd
re
act
to
pro
du
ct o
r e
sse
ntia
l pro
cess
da
ta o
ver
time.
Me
tho
ds
of
an
aly
sis
sha
ll in
clu
de
ong
oin
g t
ren
d o
r h
isto
rica
l da
ta a
na
lysi
s o
f p
rod
uct
or
pro
cess
pa
ram
ete
rs.
Th
e o
rga
niz
atio
n s
ha
ll d
ete
rmin
e w
hic
h p
ara
me
ters
to
in
clu
de
in s
uch
an
aly
sis.
1.1
3
Is m
ana
gem
ent
revi
ew
ing
th
e
we
ld c
on
tro
l sys
tem
at
a
fre
qu
en
cy d
ete
rmin
ed
by
the
co
ntr
ol p
lan
?
Ma
na
ge
me
nt
sha
ll re
vie
w t
he
we
ld p
roce
ss c
on
tro
l sy
ste
ms.
Th
e m
ana
gem
ent
revi
ew s
ha
ll in
clu
de
eff
ort
s to
d
ete
ct o
ut-o
f-co
ntr
ol c
on
diti
on
s or
ala
rm c
on
diti
on
s. T
he
p
roce
ss o
f re
vie
win
g t
he
co
ntr
ol s
yste
m s
ha
ll b
e d
ocu
me
nte
d a
nd
re
cord
ed
in th
e c
on
tro
l pla
n.
1.1
4
Are
inte
rna
l ass
ess
me
nts
b
ein
g c
om
ple
ted
on
an
an
nua
l b
asi
s, a
t a
min
imum
, u
sin
g
AIA
G W
SA
?
Th
e o
rga
niz
atio
n s
ha
ll co
nd
uct
inte
rna
l ass
ess
me
nts
on
a
n a
nn
ua
l ba
sis,
at
a m
inim
um
, u
sin
g t
he
AIA
G W
SA
. C
on
cern
s sh
all
be
ad
dre
sse
d in
a t
ime
ly m
an
ne
r.
1.1
5
Do
es t
he
Qu
alit
y D
epa
rtm
ent
re
vie
w,
ad
dre
ss,
and
d
ocu
me
nt
cust
om
er a
nd
in
tern
al c
on
cern
s?
Th
e q
ua
lity
man
ag
em
en
t sy
ste
m s
ha
ll in
clu
de
a p
roce
ss
for
do
cum
en
ting
, re
vie
win
g,
an
d a
dd
ress
ing
cu
sto
me
r co
nce
rns
and
any
oth
er
con
cern
s in
tern
al t
o th
e
org
an
iza
tion.
A d
isci
plin
ed
pro
ble
m-s
olv
ing
ap
pro
ach
sh
all
be
use
d.
1.1
1H
as
a v
alid
pro
du
ct c
ap
ab
ility
st
ud
y b
ee
n p
erf
orm
ed
initi
ally
a
nd
aft
er
pro
cess
ch
an
ge
s?
- 18 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Qu
es
tio
n
Nu
mb
er
Qu
es
tio
nR
eq
uir
em
en
ts a
nd
Gu
ida
nc
eO
bje
cti
ve
Ev
ide
nc
eN
/AS
ati
sfa
cto
ryN
ot
Sa
tis
fac
tory
Ne
ed
s I
mm
ed
iate
A
cti
on
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
1.1
6
Is t
he
re a
co
ntin
ua
l im
pro
vem
en
t p
lan
ap
plic
ab
le
to e
ach
pro
cess
de
fine
d in
th
e
sco
pe
of
the
ass
ess
me
nt?
Th
e w
eld
ing
org
an
iza
tion
sh
all
de
fine
a p
roce
ss f
or
con
tinu
al i
mp
rove
me
nt
for
the
ir w
eld
ing
pro
cess
es
ide
ntif
ied
in t
he
sco
pe
of
the
WS
A.
Th
e c
on
tinu
al
imp
rove
me
nt
pro
cess
sh
all
be
de
sig
ne
d t
o b
rin
g a
bo
ut
imp
rove
me
nts
in q
ua
lity
an
d p
rod
uct
ivity
. Id
en
tifie
d a
ctio
ns
sha
ll b
e p
rio
ritiz
ed
an
d s
ha
ll in
clu
de
tim
ing
(e
stim
ate
d
com
ple
tion
da
tes)
. T
he
org
an
iza
tion
sh
all
sho
w e
vid
en
ce
of
pro
gra
m e
ffe
ctiv
en
ess
.
1.1
7
Do
es
the
Qu
alit
y M
an
ag
er
or
de
sig
ne
e a
uth
ori
ze t
he
d
isp
osi
tion
of
ma
teri
al f
rom
q
ua
ran
tine
sta
tus?
Th
e Q
ua
lity
Ma
na
ge
r o
r d
esi
gn
ee
is r
esp
on
sib
le f
or
au
tho
rizi
ng
an
d d
ocu
me
ntin
g t
he
dis
po
sitio
n o
f q
ua
ran
tine
d m
ate
ria
l.
1.1
8
Are
th
ere
pro
ced
ure
s o
r w
ork
in
stru
ctio
ns
ava
ilab
le t
o t
he
w
eld
ing
pe
rso
nn
el t
ha
t d
efin
e
the
we
ldin
g p
roce
ss?
Th
ere
sh
all
be
pro
ced
ure
s o
r w
ork
inst
ruct
ion
s a
vaila
ble
to
w
eld
ing
pe
rso
nn
el c
ove
rin
g t
he
we
ldin
g p
roce
ss.
Th
ese
p
roce
du
res
or
wo
rk in
stru
ctio
ns
sha
ll in
clu
de
me
tho
ds
of
ad
dre
ssin
g p
ote
ntia
l em
erg
en
cie
s (s
uch
as
po
we
r fa
ilure
),
eq
uip
me
nt
sta
rt-u
p,
eq
uip
me
nt
shu
t-d
ow
n,
pro
du
ct
seg
reg
atio
n (
Se
e 2
.8),
pro
du
ct in
spe
ctio
n,
safe
ty,
ho
use
-ke
ep
ing
, a
nd
ge
ne
ral o
pe
ratin
g p
roce
du
res.
Th
ese
p
roce
du
res
or
wo
rk in
stru
ctio
ns
sha
ll b
e a
cce
ssib
le t
o
sho
p f
loo
r p
ers
on
ne
l.
1.1
9
Is t
he
re a
pre
ven
tive
m
ain
ten
an
ce p
rog
ram
?
Is
ma
inte
na
nce
da
ta b
ein
g
util
ize
d t
o f
orm
a p
red
ictiv
e
ma
inte
na
nce
pro
gra
m?
Th
e o
rga
niz
atio
n s
ha
ll h
ave
a d
ocu
me
nte
d p
reve
ntiv
e
ma
inte
na
nce
pro
gra
m f
or
pro
cess
eq
uip
me
nt
(as
ide
ntif
ied
b
y th
e P
roce
ss T
ab
les)
. T
he
pro
gra
m s
ha
ll b
e a
clo
sed
-lo
op
pro
cess
th
at
tra
cks
ma
inte
na
nce
eff
ort
s fr
om
re
qu
est
to
co
mp
letio
n t
o a
sse
ssm
en
t o
f e
ffe
ctiv
en
ess
. E
qu
ipm
en
t o
pe
rato
rs s
ha
ll h
ave
th
e o
pp
ort
un
ity t
o r
ep
ort
pro
ble
ms,
a
nd
pro
ble
ms
sha
ll a
lso
be
ha
nd
led
in a
clo
sed
-lo
op
m
an
ne
r.C
om
pa
ny
da
ta,
e.g
., d
ow
ntim
e,
qu
alit
y re
ject
s, f
irst
-tim
e-
thro
ug
h c
ap
ab
ility
, re
curr
ing
ma
inte
na
nce
wo
rk o
rde
rs,
an
d o
pe
rato
r-re
po
rte
d p
rob
lem
s, s
ha
ll b
e u
sed
to
imp
rove
th
e p
reve
ntiv
e m
ain
ten
an
ce p
rog
ram
. M
ain
ten
an
ce d
ata
sh
all
be
co
llect
ed
an
d a
na
lyze
d a
s p
art
o
f a
pre
dic
tive
ma
inte
na
nce
pro
gra
m.
Propert
y of G
enera
l Moto
rs Corp
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n
Intern
al Use
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CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Qu
es
tio
n
Nu
mb
er
Qu
es
tio
nR
eq
uir
em
en
ts a
nd
Gu
ida
nc
eO
bje
cti
ve
Ev
ide
nc
eN
/AS
ati
sfa
cto
ryN
ot
Sa
tis
fac
tory
Ne
ed
s I
mm
ed
iate
A
cti
on
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
1.2
0
Ha
s th
e w
eld
ing
org
an
iza
tion
d
eve
lop
ed
a c
ritic
al s
pa
re p
art
lis
t a
nd
are
th
e p
art
s a
vaila
ble
to
min
imiz
e p
rod
uct
ion
d
isru
ptio
ns?
Th
e w
eld
ing
org
an
iza
tion
sh
all
de
velo
p a
nd
ma
inta
in a
cr
itica
l sp
are
pa
rts
list
an
d s
ha
ll e
nsu
re t
he
ava
ilab
ility
of
such
pa
rts
to m
inim
ize
pro
du
ctio
n d
isru
ptio
ns.
1.2
1
Ho
w d
oe
s th
e o
rga
niz
atio
n
do
cum
en
t a
nd
re
spo
nd
to
q
ua
lity
spill
s, n
on
con
form
an
ce,
cust
om
er
con
cern
s?
Re
act
ion
pla
ns
are
to
be
fo
llow
ed
pe
r th
e c
on
tro
l pla
n a
nd
P
FM
EA
or,
in t
he
ca
se o
f n
ew
ly in
de
ntif
ied
issu
es
PF
ME
A
an
d c
on
tro
l pla
n m
ust
be
up
da
ted
to
re
flect
th
e n
ew
fa
ilure
m
od
e a
nd
re
act
ion
ste
ps
take
n.
1.2
2W
ha
t is
th
e p
roce
ss d
evi
atio
n
req
uir
em
en
ts o
f yo
ur
cust
om
er?
If t
he
re a
re t
o b
e c
ha
ng
es
in p
roce
ss o
uts
ide
of
the
cu
rre
nt
con
tro
l pla
n a
nd
last
ag
ree
d u
po
n p
roce
ss a
nd
pa
rts
sig
n
off
, d
o y
ou
kn
ow
wh
at
you
r cu
sto
me
r re
qu
ire
me
nts
are
, h
ave
yo
u n
otif
ied
yo
ur
cust
om
er,
an
d d
o y
ou
ha
ve
cust
om
er
ap
pro
val p
rio
r to
ma
kin
g t
he
ch
an
ge
?
1.2
3Is
th
ere
a s
yste
m in
pla
ce t
o
au
tho
rize
re
pro
cess
ing
an
d
rep
air
? I
s it
do
cum
en
ted
?
Th
e q
ua
lity
ma
na
ge
me
nt
syst
em
sh
all
incl
ud
e a
d
ocu
me
nte
d p
roce
ss f
or
rep
roce
ssin
g a
nd
re
pa
ir t
ha
t sh
all
incl
ud
e a
uth
ori
zatio
n f
rom
a c
ust
om
er
de
sig
na
ted
in
div
idu
al.
Th
e p
roce
ss s
ha
ll d
esc
rib
e p
rod
uct
ch
ara
cte
rist
ics
for
wh
ich
re
pro
cess
ing
is a
llow
ed
as
we
ll a
s th
ose
ch
ara
cte
rist
ics
for
wh
ich
re
pro
cess
ing
is n
ot
pe
rmis
sib
le.
An
y re
pro
cess
ing
act
ivity
sh
all
req
uir
e a
ne
w
pro
cess
ing
co
ntr
ol s
he
et
issu
ed
by
qu
alif
ied
te
chn
ica
l p
ers
on
ne
l de
no
ting
th
e n
ece
ssa
ry w
eld
ing
mo
difi
catio
ns.
R
eco
rds
sha
ll cl
ea
rly
ind
ica
te w
he
n a
nd
ho
w a
ny
ma
teri
al
ha
s b
ee
n r
ep
roce
sse
d.
Th
e Q
ua
lity
Ma
na
ge
r o
r a
d
esi
gn
ee
sh
all
au
tho
rize
th
e r
ele
ase
of
rep
roce
sse
d
pro
du
ct.
- 20 -
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y of G
enera
l Moto
rs Corp
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n
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al Use
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Qu
es
tio
n
Nu
mb
er
Qu
es
tio
nR
eq
uir
em
en
ts a
nd
Gu
ida
nc
eO
bje
cti
ve
Ev
ide
nc
eN
/AS
ati
sfa
cto
ryN
ot
Sa
tis
fac
tory
Ne
ed
s I
mm
ed
iate
A
cti
on
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
2.1
Do
es
the
fa
cilit
y e
nsu
re t
ha
t th
e d
ata
en
tere
d in
th
e
rece
ivin
g s
yste
m m
atc
he
s th
e
info
rma
tion
on
th
e c
ust
om
er's
sh
ipp
ing
do
cum
en
ts?
It is
cri
tica
l th
at
all
cust
om
er
req
uir
em
en
ts a
nd
lot
ide
ntif
ica
tion
be
ad
eq
ua
tely
tra
nsf
err
ed
to
inte
rna
l we
ldin
g
do
cum
en
ts.
Th
e f
aci
lity
sha
ll e
nsu
re t
ha
t th
e d
ata
en
tere
d
in t
he
re
ceiv
ing
sys
tem
ma
tch
th
e in
form
atio
n o
n t
he
cu
sto
me
r's s
hip
pin
g d
ocu
me
nts
. D
ocu
me
nte
d p
roce
sse
s a
nd
evi
de
nce
of
com
plia
nce
sh
all
exi
st,
e.g
., s
ho
p
tra
vele
rs,
wo
rk o
rde
rs,
etc
. S
om
etim
es
the
ma
teri
al
rece
ive
d d
oe
s n
ot
pre
cise
ly c
orr
esp
on
d t
o c
ust
om
er
ship
pin
g d
ocu
me
nts
. T
he
fa
cilit
y sh
all
ha
ve a
de
taile
d
pro
cess
in p
lace
to
re
solv
e r
ece
ivin
g d
iscr
ep
an
cie
s.T
he
re
qu
ire
me
nts
sta
ted
ab
ove
als
o a
pp
ly t
o c
ap
tive
w
eld
ing
de
pa
rtm
en
ts.
Th
is p
roce
ss r
efe
rs t
o r
ece
ivin
g a
nd
ship
pin
g t
he
pa
rts
in a
nd
ou
t o
f th
e w
eld
ing
de
pa
rtm
en
t.
2.2
Is p
rod
uct
cle
arl
y id
en
tifie
d
an
d s
tag
ed
th
rou
gh
ou
t th
e
we
ldin
g p
roce
ss?
Pro
ced
ure
s fo
r p
art
an
d c
on
tain
er
ide
ntif
ica
tion
he
lp t
o
avo
id in
corr
ect
pro
cess
ing
or
mix
ing
of
lots
. A
pp
rop
ria
te
loca
tion
an
d s
tag
ing
with
in t
he
fa
cilit
y a
lso
he
lp t
o e
nsu
re
tha
t o
rde
rs a
re n
ot
ship
pe
d u
ntil
all
req
uir
ed
op
era
tion
s a
r ep
erf
orm
ed
. C
ust
om
er
pro
du
ct s
ha
ll b
e c
lea
rly
ide
ntif
ied
a
nd
sta
ge
d t
hro
ug
ho
ut
the
we
ldin
g p
roce
ss.
No
n-w
eld
ed
, in
-pro
cess
, a
nd
fin
ish
ed
pro
du
ct s
ha
ll b
e p
rop
erl
y se
gre
ga
ted
an
d id
en
tifie
d.
All
ma
teri
al s
ha
ll b
e s
tag
ed
in a
de
dic
ate
d a
nd
cle
arl
y d
efin
ed
are
a.
2.3
Is lo
t tr
ace
ab
ility
an
d in
teg
rity
m
ain
tain
ed
th
rou
gh
ou
t a
ll p
roce
sse
s?
Ou
t-g
oin
g lo
t(s)
sh
all
be
tra
cea
ble
to
th
e in
com
ing
lot(
s).
Th
e d
isci
plin
e o
f p
reci
sely
ide
ntif
yin
g lo
ts a
nd
lin
kin
g a
ll p
ert
ine
nt
info
rma
tion
to
th
em
en
ha
nce
s th
e a
bili
ty t
o d
o
roo
t ca
use
an
aly
sis
an
d c
on
tinu
al i
mp
rove
me
nt.
2.4
Are
pro
ced
ure
s a
de
qu
ate
to
p
reve
nt
mo
vem
en
t o
f n
on
-co
nfo
rmin
g p
rod
uct
into
th
e
pro
du
ctio
n s
yste
m?
Th
e c
on
tro
l of
susp
ect
or
no
n-c
on
form
ing
pro
du
ct is
re
qu
ire
d t
o p
reve
nt
ina
dve
rte
nt
ship
me
nt
or
con
tam
ina
tion
o
f o
the
r lo
ts.
Pro
ced
ure
s sh
all
be
ad
eq
ua
te t
o p
reve
nt
mo
vem
en
t o
f n
on
-co
nfo
rmin
g p
rod
uct
into
th
e p
rod
uct
ion
sy
ste
m.
Pro
ced
ure
s sh
all
exi
st a
dd
ress
ing
pro
pe
r d
isp
osi
tion
, p
rod
uct
ide
ntif
ica
tion
, a
nd
tra
ckin
g o
f m
ate
ria
l flo
w in
an
d o
ut
of
the
ho
ld a
rea
. A
no
n-c
on
form
ing
ho
ld
are
a s
ha
ll b
e c
lea
rly
de
sig
na
ted
to
ma
inta
in s
eg
reg
atio
n o
f su
ch m
ate
ria
l.
Se
cti
on
2 -
Flo
or
an
d M
ate
ria
l H
an
dli
ng
Re
sp
on
sib
ilit
y
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Qu
es
tio
n
Nu
mb
er
Qu
es
tio
nR
eq
uir
em
en
ts a
nd
Gu
ida
nc
eO
bje
cti
ve
Ev
ide
nc
eN
/AS
ati
sfa
cto
ryN
ot
Sa
tis
fac
tory
Ne
ed
s I
mm
ed
iate
A
cti
on
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
2.5
Are
co
nta
ine
rs f
ree
of
in
ap
pro
pri
ate
ma
teri
al a
nd
co
nta
min
an
ts?
Co
nta
ine
rs h
an
dlin
g c
ust
om
er
pro
du
ct s
ha
ll b
e f
ree
of
ina
pp
rop
ria
te m
ate
ria
l an
d c
on
tam
ina
nts
. A
fte
r e
mp
tyin
g
an
d b
efo
re r
e-u
sin
g c
on
tain
ers
, co
nta
ine
rs s
ha
ll b
e
insp
ect
ed
to
en
sure
th
at
all
pa
rts
an
d in
ap
pro
pri
ate
m
ate
ria
l ha
ve b
ee
n r
em
ove
d.
Th
e s
ou
rce
of
ina
pp
rop
ria
te
ma
teri
al s
ha
ll b
e id
en
tifie
d a
nd
ad
dre
sse
d.
Th
is is
to
e
nsu
re t
ha
t n
o n
on
con
form
ing
we
lde
d p
art
s o
r in
ap
pro
pri
ate
ma
teri
al c
on
tam
ina
te t
he
fin
ish
ed
lot.
2.6
Is p
art
loa
din
g s
pe
cifie
d,
do
cum
en
ted
an
d c
on
tro
lled
?
Lo
ad
ing
pa
ram
ete
rs s
ha
ll b
e s
pe
cifie
d,
do
cum
en
ted
, a
nd
co
ntr
olle
d.
Exa
mp
les
incl
ud
e p
art
loa
d s
eq
ue
nce
an
d
cla
mp
se
qu
en
ce.
2.7
Is t
he
re a
co
nta
inm
en
t re
act
ion
pla
n a
nd
are
o
pe
rato
rs t
rain
ed
in t
he
p
roce
ss?
Op
era
tors
sh
all
be
tra
ine
d in
ma
teri
al h
an
dlin
g,
con
tain
me
nt
act
ion
, a
nd
pro
du
ct s
eg
reg
atio
n in
th
e e
ven
t o
f a
n e
qu
ipm
en
t e
me
rge
ncy
incl
ud
ing
po
we
r fa
ilure
.
Tra
inin
g s
ha
ll b
e d
ocu
me
nte
d.
Wo
rk in
stru
ctio
ns
spe
cific
ally
ad
dre
ssin
g p
ote
ntia
l typ
es
of
eq
uip
me
nt
em
erg
en
cie
s a
nd
fa
ilure
s sh
all
be
acc
ess
ible
to
an
d
un
de
rsto
od
by
eq
uip
me
nt
op
era
tors
. T
he
se in
stru
ctio
ns
sha
ll a
dd
ress
co
nta
inm
en
t/re
act
ion
pla
ns
rela
ted
to
all
ele
me
nts
of
the
we
ldin
g p
roce
ss.
Evi
de
nce
sh
all
exi
st
sho
win
g d
isp
osi
tion
an
d t
race
ab
ility
of
aff
ect
ed
pro
du
ct.
Un
pla
nn
ed
or
em
erg
en
cy d
ow
ntim
e g
rea
tly r
ais
es
the
ris
k o
f im
pro
pe
r p
roce
ssin
g.
2.8
Is t
he
ha
nd
ling
, st
ora
ge
an
d
pa
cka
gin
g a
de
qu
ate
to
p
rese
rve
pro
du
ct q
ua
lity?
Th
e w
eld
er'
s lo
ad
ing
sys
tem
, in
-pro
cess
ha
nd
ling
, a
nd
sh
ipp
ing
pro
cess
sh
all
be
ass
ess
ed
fo
r ri
sk o
f p
art
d
am
ag
e o
r o
the
r q
ua
lity
con
cern
s.O
the
r p
ract
ice
s su
ch a
s st
ack
ing
of
ove
rlo
ad
ed
co
nta
ine
rs
can
als
o in
cre
ase
th
e r
isk
of
pa
rt d
am
ag
e.
2.9
Are
pla
nt
cle
an
line
ss,
ho
use
kee
pin
g,
en
viro
nm
en
tal
an
d w
ork
ing
co
nd
itio
ns
con
du
cive
to
co
ntr
ol a
nd
im
pro
ved
qu
alit
y?
Pla
nt
cle
an
line
ss,
ho
use
kee
pin
g,
en
viro
nm
en
tal,
an
d
wo
rkin
g c
on
diti
on
s sh
all
be
co
nd
uci
ve t
o c
on
tro
llin
g a
nd
im
pro
vin
g q
ua
lity.
T
he
we
ldin
g o
rga
niz
atio
n s
ha
ll e
valu
ate
su
ch c
on
diti
on
s a
nd
th
eir
eff
ect
on
qu
alit
y.
A
ho
use
kee
pin
g p
olic
y sh
all
be
cle
arl
y d
efin
ed
an
d
exe
cute
d.
Th
e f
aci
lity
sha
ll b
e r
evi
ew
ed
fo
r co
nd
itio
ns
tha
t a
re d
etr
ime
nta
l to
qu
alit
y p
roce
ssin
g s
uch
as
loo
se p
art
s o
n f
loo
r, c
on
tam
ina
nts
, o
il, in
ad
eq
ua
te p
lan
t lig
htin
g,
fum
es,
etc
.
- 22 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 23 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Qu
es
tio
n
Nu
mb
er
Qu
es
tio
nR
eq
uir
em
en
ts a
nd
Gu
ida
nc
eO
bje
cti
ve
Ev
ide
nc
eN
/AS
ati
sfa
cto
ryN
ot
Sa
tis
fac
tory
Ne
ed
s I
mm
ed
iate
A
cti
on
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
2.1
0
Are
pa
rts
fre
e f
rom
co
nta
min
an
ts t
ha
t w
ou
ld b
e
de
trim
en
tal t
o t
he
qu
alit
y o
f th
ew
eld
ing
pro
cess
es,
su
bse
qu
en
t p
roce
sse
s, o
r th
e
pro
du
ct?
Pa
rts
sha
ll b
e f
ree
fro
m c
on
tam
ina
nts
th
at
are
de
trim
en
tal
to t
he
qu
alit
y o
f th
e w
eld
ing
pro
cess
es,
su
bse
qu
en
t p
roce
sse
s, o
r th
e p
rod
uct
. I
f a
pp
lica
ble
, p
re-w
ash
an
d
po
st-w
ash
pa
ram
ete
rs
sha
ll b
e m
on
itore
d a
nd
d
ocu
me
nte
d.
3.1
Are
th
e f
aci
litie
s su
ffic
ien
t fo
r th
e w
eld
ing
op
era
tion
?
Th
is c
ou
ld in
clu
de
bu
t is
no
t lim
ited
to
, fa
cilit
ies
cap
ab
ilitie
s su
ch a
s sa
fely
, e
nvi
ron
me
nta
l re
gu
latio
ns/
pra
ctic
e,
suff
icie
nt
inco
min
g p
ow
er
(ba
lan
ce
an
d lo
ad
ing
), a
ir (
sizi
ng
, fil
teri
ng
an
d c
lea
nlin
ess
), w
ate
r,
po
we
r su
pp
ly g
rou
nd
ing
pe
r O
EM
an
d r
eg
ula
tory
sp
eci
fica
tion
s, g
as
mix
ing
sys
tem
(e
qu
ipm
en
t a
nd
siz
ing
),
ven
tila
tion
, a
nd
ad
eq
ua
te li
gh
ting
.
3.2
Are
th
e p
ow
er
sup
plie
s su
ffic
ien
tly s
ize
d?
Th
e p
ow
er
sup
ply
sh
ou
ld b
e a
de
qu
ate
fo
r th
e
ma
nu
fact
uri
ng
pro
cess
with
co
nsi
de
ratio
n n
ot
limite
d t
o
ou
tpu
t e
ne
rgy,
du
ty c
ycle
, co
olin
g,
flow
ra
tes
an
d
gro
un
din
g.
3.3
Are
pro
cess
eq
uip
me
nt
calib
ratio
ns
an
d/o
r ve
rific
atio
n
cert
ifie
d,
do
cum
en
ted
, a
vaila
ble
, a
nd
cu
rre
nt?
Th
e c
alib
ratio
n a
nd
ce
rtifi
catio
n o
f th
e p
roce
ss e
qu
ipm
en
t sh
all
be
ch
eck
ed
at
reg
ula
r sp
eci
fied
inte
rva
ls.
Re
fer
to
the
ap
plic
ab
le P
roce
ss T
ab
les.
3.4
Ha
s a
pre
ven
tativ
e
ma
inte
na
nce
pro
gra
m b
ee
n
est
ab
lish
ed
an
d d
ocu
me
nte
d?
Su
pp
lier
sha
ll h
ave
a p
reve
nta
tive
ma
inte
na
nce
pro
gra
m
tha
t is
do
cum
en
ted
an
d im
ple
me
nte
d.
Re
fer
to S
ect
ion
1
.19
an
d t
he
ap
plic
ab
le P
roce
ss T
ab
les.
3.5
Ha
ve t
he
ne
cess
ary
re
pla
cem
en
t p
art
s a
nd
p
roce
ss c
on
sum
ab
les
be
en
id
en
tifie
d a
nd
ma
de
re
ad
ily
ava
ilab
le?
Th
e r
ep
lace
me
nt
pa
rts
an
d p
roce
ss c
on
sum
ab
les
sha
ll b
e
ide
ntif
ied
, m
ain
tain
ed
in t
he
ap
pro
pri
ate
vo
lum
es
an
d
pro
pe
r st
ora
ge
. C
on
sum
ab
les
mu
st b
e o
n t
he
cu
sto
me
r's
ap
pro
ved
so
urc
e li
st (
if a
pp
lica
ble
). R
efe
r to
th
e a
pp
lica
ble
P
roce
ss T
ab
les,
Se
ctio
n 2
.0 a
nd
Se
ctio
n 1
.19
. T
his
sh
all
be
ca
ptu
red
in t
oo
ls s
uch
as
the
se
t u
p p
roce
du
re,
PF
ME
Aa
nd
Co
ntr
ol P
lan
s.
It s
ho
uld
be
incl
ud
ed
in t
he
laye
red
p
roce
ss a
ud
it o
r o
the
r si
mila
r ty
pe
qu
alit
y re
vie
w p
roce
ss.
3.6
Are
th
e p
roce
ss,
eq
uip
me
nt,
a
nd
sa
fety
ala
rm c
he
cks
be
ing
te
ste
d a
t th
e r
eq
uir
ed
fr
eq
ue
ncy
or
aft
er
an
y re
pa
ir o
rre
bu
ild?
Th
e w
eld
ing
op
era
tion
sh
all
ha
ve a
list
of
we
ldin
g
pro
cess
, e
qu
ipm
en
t, a
nd
sa
fety
ala
rms.
Th
ese
ala
rms
sha
ll b
e in
div
idu
ally
te
ste
d a
t th
e r
eq
uir
ed
fre
qu
en
cy a
s lis
ted
in t
he
co
ntr
ol p
lan
, a
nd
aft
er
an
y re
pa
ir,
pro
cess
ch
an
ge
or
reb
uild
. T
he
se c
he
cks
sha
ll b
e d
ocu
me
nte
d.
Se
cti
on
3 -
Eq
uip
me
nt
/ F
ac
ilit
ies
/Co
ntr
ols
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Qu
es
tio
n
Nu
mb
er
Qu
es
tio
nR
eq
uir
em
en
ts a
nd
Gu
ida
nc
eO
bje
cti
ve
Ev
ide
nc
eN
/AS
ati
sfa
cto
ryN
ot
Sa
tis
fac
tory
Ne
ed
s I
mm
ed
iate
A
cti
on
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
4.1
Is t
he
re a
re
cord
of
the
de
sig
n
an
d s
et-
up
of
the
fixtu
re?
Su
pp
lier
sha
ll ha
ve d
ocu
me
nta
tion
of
the
fix
ture
de
sig
n,
tha
t a
re s
tore
d p
rop
erly
an
d a
cce
ssib
le.
Pro
pe
r id
en
tific
atio
n a
nd
re
visi
on
leve
l on
th
e f
ixtu
re o
r re
late
d to
th
e f
ixtu
re.
Do
cum
en
ted
fix
ture
se
t-u
p (
i.e.,
cla
mp
s, p
ins,
lo
catin
g d
evi
ces)
4.2
Is t
he
po
sitio
nin
g o
f e
ach
pa
rt
be
ing
co
ntr
olle
d?
A m
eth
od
to
de
tect
pro
pe
r fix
ture
an
d p
art
po
sitio
n is
re
qu
ired
fo
r e
ach
pa
rt,
such
as
the
use
of
pro
xim
ity
switc
hes
, o
ptic
al s
en
sors
, m
ech
an
ical
pro
bes
, p
art
p
rese
nce
or
po
ke y
oke
s.,
etc
.
4.3
Ha
s fix
turi
ng
/to
olin
g
pre
ven
tativ
e m
ain
tena
nce
p
rog
ram
be
en
est
ab
lish
ed
?
Su
pp
lier
sha
ll ha
ve a
pre
ven
tativ
e m
ain
ten
an
ce p
rog
ram
th
at
is d
ocu
me
nte
d a
nd
imp
lem
en
ted
. R
efe
r to
Se
ctio
n
1.1
8 a
nd t
he
ap
plic
ab
le P
roce
ss T
able
s. E
xam
ple
s:
cle
an
ing
, d
eg
rea
sin
g,
an
d f
ixtu
rin
g in
teg
rity
.
4.4
Are
the
fix
ture
co
mp
on
en
ts
rob
ust?
Ga
s, a
ir,
sen
sors
, co
ntro
l ca
ble
s, e
tc.
are
ad
eq
ua
tely
p
rote
cte
d f
or
the
pro
cess
en
viro
nm
en
t.
4.5
Are
th
e to
olin
g c
om
po
ne
nts
d
esi
gn
ed
fo
r th
e w
eld
ing
p
roce
ss?
Fix
turi
ng
/to
olin
g w
as
dev
elo
pe
d c
on
sid
eri
ng
mov
em
en
t,
rea
ch,
acc
ess
ibili
ty,
too
l ce
nte
r p
oin
t, m
ain
ten
an
ce,
an
d
erg
on
om
ics
(ma
nu
al,
au
tom
atic
, a
nd
ro
bo
tics)
5.1
Do
es
we
ldin
g o
pera
tion
incl
ud
e t
he
follo
win
g?
Ide
ntif
y th
e p
roce
ss c
on
tro
l eq
uip
me
nt
ne
cess
ary
to
m
on
itor,
co
ntr
ol a
nd
pro
vid
e f
ee
db
ack
on
all
ess
en
tial
pro
cess
va
ria
ble
s a
s lis
ted
be
low
an
d in
th
e a
pp
lica
ble
P
roce
ss T
ab
les.
5.1
.1L
og
ic h
as b
ee
n e
sta
blis
he
d t
o e
ffe
ctiv
ely
ide
ntif
y a
nd
a
dd
ress
pro
cess
or
eq
uip
me
nt
fau
lts.
5.1
.2W
ith o
ver
rid
es
or
rese
ts,
log
s m
ust
be
mai
nta
ine
d.
5.1
.3W
eld
fa
ults
au
dib
le,
visi
ble
an
d li
ne
sh
ut
do
wn
.
5.1
.4A
t w
eld
cyc
le in
terr
up
t, p
art
mu
st n
ot b
e r
emo
ved
or
pa
sse
d u
ntil
dis
po
sitio
ne
d b
y a
pp
rop
ria
te p
erso
nn
el.
5.1
.5C
alib
ratio
n o
f m
ete
rs a
nd
sys
tem
co
ntr
ols
.
5.1
.6
Inte
r-lo
ckin
g o
f pre
vio
us
op
era
tion
s h
ave
occ
urr
ed
an
d
qu
alit
y o
f p
art
s h
as
be
en
ve
rifie
d b
efo
re t
he
ne
xt o
pe
ratio
n
be
gin
s.
5.1
.7S
ecu
re b
acku
ps
of
all
pro
gra
ms
an
d p
roce
du
res
(ele
ctro
nic
pre
ferr
ed).
5.1
.8H
igh
/Lo
w li
mit
ala
rms
est
ab
lish
ed
by
act
ua
l da
ta.
5.1
.9P
roce
ss v
ari
ab
les
ha
ve b
ee
n d
efin
ed
an
d d
eve
lop
ed
by
da
ta a
nd s
ho
wn
to
be
sta
tistic
ally
ca
pa
ble
.
5.1
.10
Acc
ep
tab
le t
race
ab
ility
(se
que
nce
/da
te c
od
ing
)
Se
cti
on
5 -
PR
OC
ES
S C
ON
TR
OL
S A
ND
CO
NF
IRM
AT
ION
Se
cti
on
4 -
TO
OL
ING
/FIX
TU
RIN
G
- 24 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Qu
es
tio
n
Nu
mb
er
Qu
est
ion
Re
qu
ire
me
nts
an
d G
uid
an
ce
Ob
jec
tiv
e E
vid
en
ce
N/A
Sa
tis
fac
tory
No
t S
atis
fac
tory
Ne
ed
s I
mm
ed
iate
A
cti
on
As
se
ss
me
nt
Sp
ec
ial
Pro
ce
ss
: W
eld
ing
Sy
ste
m A
ss
es
sm
en
t
5.1
.11
All
too
ling
an
d p
roce
ss c
ha
ng
es
are
do
cum
en
ted
.
5.1
.12
Doc
um
en
ted
wel
din
g p
roce
dur
es
for
ea
ch w
eld
loca
tion
a
nd
ea
ch p
roce
ss v
ari
ab
le.
5.1
.13
Ch
an
ge
ove
r p
roce
du
re (
fille
r m
ate
ria
l, fix
ture
s)
5.1
.14
Mu
st h
ave
do
cum
en
ted
sta
rt-u
p a
nd
sh
ut-
do
wn
pro
ced
ure
.
5.2
Are
pro
cess
co
ntr
ol
pa
ram
ete
rs m
on
itore
d a
t e
sta
blis
he
d f
req
ue
nci
es?
Pro
cess
con
tro
l pa
ram
ete
rs s
hall
be
mo
nito
red
pe
r fr
eq
ue
nci
es
est
ab
lish
ed
in t
he
co
ntr
ol p
lan
. A
n a
pp
rop
ria
te
pe
rso
n s
ha
ll ve
rify
th
e p
roce
ss c
on
tro
l pa
ram
ete
rs.
M
an
ag
em
en
t re
vie
w is
re
qu
ire
d p
er
Qu
est
ion
1.1
3.
5.3
Ho
w d
oe
s th
e o
rga
niz
atio
n
revi
ew
an
d r
eac
t to
ou
t o
f co
ntr
ol/s
peci
fica
tion
p
ara
me
ters
?
Are
th
ere
do
cum
en
ted
re
actio
n p
lan
s w
ith a
pp
ropr
iate
le
vels
of
con
tain
me
nt
for
bo
th o
ut
of
con
tro
l an
d o
ut
of
tole
ran
ce p
roce
ss p
ara
me
ters
?
Is t
he
re d
ocu
me
nte
d
evi
de
nce
th
at
rea
ctio
n p
lan
s a
re f
ollo
we
d?
5.4
Ho
w d
oe
s th
e o
rga
niz
atio
n
ha
nd
le c
han
ge
s to
pro
cess
co
ntr
ol p
ara
me
ters
aft
er
initi
al
cust
om
er
ap
pro
val?
Th
ere
sh
all
be
a h
iera
rch
y e
sta
blis
he
d f
or
ma
kin
g a
nd
ap
pro
vin
g p
roce
ss c
ha
ng
es.
E
ach
pro
cess
sh
ou
ld b
e
act
ed
on
acc
ord
ing
to
th
e le
vel o
f ch
an
ge
. R
evi
ew
p
roce
ss c
ha
ng
es
with
yo
ur
cust
om
er.
5.5
Are
In
-Pro
cess
an
d F
ina
l T
est
s p
erf
orm
ed
at
est
ab
lish
ed
fre
qu
en
cie
s?
In-P
roce
ss a
nd
Fin
al T
est
s sh
all
be
pe
rfo
rmed
per
fr
eq
ue
nci
es
in t
he
co
ntr
ol p
lan
as
ag
ree
d u
po
n b
etw
ee
n
the
su
pp
lier
an
d t
he
cu
sto
mer
.
5.6
Are
we
ld q
ua
lity
req
uir
em
en
ts
cle
arl
y d
efin
ed
pe
r cu
sto
me
r sp
eci
fica
tion
s?
We
ld q
ua
lity
req
uir
em
en
ts p
er
inte
rna
l an
d c
ust
om
er
spe
cific
atio
ns,
suc
h a
s b
ut
no
t lim
ited
to
th
e f
ollo
win
g
test
ing
me
tho
do
logy
:
5.6
.1C
ut
an
d e
tch
5.6
.2P
art
loca
tion
, w
arp
ing
, g
ap
, a
nd
d
ime
nsi
on
al
req
uir
em
en
ts
5.6
.3C
orr
ect
nu
mb
er
of
we
lds
5.6
.4W
eld
len
gth
/siz
e
5.6
.5W
eld
loca
tion
5.6
.6N
on D
est
ruct
ive
Te
stin
g (
ND
T)
5.6
.7S
pa
tte
r, u
nd
erc
ut,
po
rosi
ty,
disc
on
tinu
itie
s,.
5.6
.8W
eld
dir
ect
ion
co
nfir
ma
tion
5.6
.9D
est
ruct
ive
te
stin
g
5.6
.10
Ad
diti
ona
l te
stin
g
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
- 26 -
Instructions for completing the Job Audit
The organization is to complete a minimum of one welding 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, etc.). It is recommended that the job audit be performed at the end of the welding system assessment.
The job audit is not the only or main focus of the WSA. The other five sections on Management Responsibility and Quality Planning, Floor and Material Handling Responsibility, and Equipment/Facilities/Control, Tooling/Fixturing, and Process Controls and Confirmation are equally if not even more important. The job audit of one part, one weld process, is not sufficient to use as a basis to complete the other sections of the complete WSA.
The job audit is a compliance type audit/review of a specific part and its related paperwork and processing, including welding equipment and processing records for that job from the beginning receipt of a part through processing in the welding operation and inspection to packaging. Parts shall be taken from the shipping area at the dock or the end of the welding 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 checked shall represent a major weld operation such as an individual operation, cell, or assembly line. In subsequent welding system assessments, different parts and welding processes shall be checked.
The specific welding processing parameters (applies to 6.1 and 6.13 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 production records/compliance/inspection. These steps can be compared to those in the Welding System Assessment for the actual job/welding process being reviewed for compliance. The welding records for the actual time frame/shift etc. that the job was processed shall also be checked. The actual welding equipment and instrumentation certification shall be verified as being in compliance to the appropriate equipment requirements in the equipment section.
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 27 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Se
cti
on
6 -
Jo
b A
ud
it
Jo
b I
de
nti
ty:
Cu
sto
me
r:S
ho
p O
rde
r N
um
be
r:P
art
Nu
mb
er:
Pa
rt D
es
cri
pti
on
:B
as
e M
eta
l S
pe
cif
ica
tio
ns
:F
ille
r M
eta
l S
pe
cif
ica
tio
n (
if r
eq
uir
ed
):W
eld
ing
Pro
ce
ss
(es
):
Qu
est
ion
#Jo
b A
ud
it Q
ue
stio
nR
ela
ted
WS
A Q
ue
stio
n #
Cu
sto
me
r o
r In
tern
al
Re
qu
ire
me
nt
Job
(S
ho
p)
Ord
er
or
Re
fere
nce
Do
cum
en
tatio
n
Re
qu
ire
me
nt
Act
ua
l Co
nd
itio
n
(Ob
ject
ive
Evi
de
nce
)P
ass
/ F
ail
/ N
/A
6.1
Ha
s th
e w
eld
ing
op
era
tion
ide
ntif
ied
th
e
pro
cess
co
ntr
ol e
qu
ipm
en
t n
ece
ssa
ry t
o
mo
nito
r, c
on
tro
l an
d p
rovi
de
fe
ed
ba
ck o
n a
ll e
sse
ntia
l pro
cess
va
ria
ble
s a
s lis
ted
in t
he
a
pp
lica
ble
Pro
cess
Ta
ble
s?
1.8
5.1
5.2
6.2
Ha
s th
e lo
gic
be
en
est
ab
lish
ed
to
eff
ect
ive
ly
ide
ntif
y a
nd
ad
dre
ss p
roce
ss o
r e
qu
ipm
en
t fa
ults
?
5.1
6.3
Are
ove
r ri
de
s o
r re
sets
log
s m
ain
tain
ed
?
5.1
.2
6.4
Are
we
ld f
au
lts a
ud
ible
, vi
sib
le a
nd
do
es
the
lin
e s
hu
t d
ow
n?
5.1
.3
6.5
If t
he
we
ld c
ycle
is in
terr
up
ted
, is
th
e p
art
co
ntr
olle
d o
r co
nta
ine
d u
ntil
dis
po
sitio
ne
d b
y a
pp
rop
ria
te p
ers
on
ne
l?
2.7
5.1
.4
6.6
Are
th
e m
ete
rs a
nd
fe
ed
ba
ck c
on
tro
ls
calib
rate
d p
er
est
ab
lish
ed
fre
qu
en
cie
s?
5.1
.53
.3
6.7
If a
pp
lica
ble
, is
th
ere
an
inte
r-lo
ckin
g o
f th
e
pre
vio
us
op
era
tion
an
d h
as
the
qu
alit
y o
f p
art
s b
ee
n v
eri
fied
?
5.1
. 6
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Se
cti
on
6 -
Jo
b A
ud
it
Jo
b I
de
nti
ty:
Cu
sto
me
r:S
ho
p O
rde
r N
um
be
r:P
art
Nu
mb
er:
Pa
rt D
es
cri
pti
on
:B
as
e M
eta
l S
pe
cif
ica
tio
ns
:F
ille
r M
eta
l S
pe
cif
ica
tio
n (
if r
eq
uir
ed
):W
eld
ing
Pro
ce
ss
(es
):
Qu
est
ion
#Jo
b A
ud
it Q
ue
stio
nR
ela
ted
WS
A Q
ue
stio
n #
Cu
sto
me
r o
r In
tern
al
Re
qu
ire
me
nt
Job
(S
ho
p)
Ord
er
or
Re
fere
nce
Do
cum
en
tatio
n
Re
qu
ire
me
nt
Act
ua
l Co
nd
itio
n
(Ob
ject
ive
Evi
de
nce
)P
ass
/ F
ail
/ N
/ A
6.8
Are
th
ere
se
cure
ba
cku
ps
of
all
pro
gra
ms
an
d p
roce
du
res
(ele
ctro
nic
pre
ferr
ed
)?
5.1
.7
6.9
Are
hig
h/lo
w li
mit
ala
rms
est
ab
lish
ed
by
act
ua
l da
ta.
5.1
.85
.1.1
6.1
0
Ha
ve p
roce
ss v
ari
ab
les
be
en
de
fine
d a
nd
d
eve
lop
ed
by
da
ta a
nd
sh
ow
n t
o b
e
sta
tistic
ally
ca
pa
ble
?
5.1
.9
6.1
1Is
th
ere
acc
ep
tab
le t
race
ab
ility
(s
eq
ue
nce
/da
te c
od
ing
)?
5.1
.10
5.1
.11
2.3
2.7
6.1
2Is
th
ere
tra
cea
bili
ty o
f a
ll p
roce
ss a
nd
to
olin
g c
ha
ng
es?
4.1
5.1
.11
5.4
6.1
3A
re t
he
re d
ocu
me
nte
d w
eld
ing
pro
ced
ure
s fo
r e
ach
we
ld lo
catio
n a
nd
ea
ch p
roce
ss
vari
ab
le?
5.1
.12
1.5
1.1
0
6.1
4Is
th
ere
a d
ocu
me
nte
d c
ha
ng
e o
ver
pro
ced
ure
(fil
ler
ma
teri
al,
fixtu
res)
?
1.5
5.1
.13
3.6
6.1
5Is
th
ere
a d
ocu
me
nte
d s
tart
-up
an
d s
hu
t-d
ow
n p
roce
du
re?
1.5
1.1
05
.1.1
4
6.1
6 A
re p
roce
ss c
on
tro
l pa
ram
ete
rs m
on
itore
d
at
est
ab
lish
ed
fre
qu
en
cie
s?
5. 2
- 28 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 29 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Se
cti
on
6 -
Jo
b A
ud
it
Jo
b I
de
nti
ty:
Cu
sto
me
r:S
ho
p O
rde
r N
um
be
r:P
art
Nu
mb
er:
Pa
rt D
es
cri
pti
on
:B
as
e M
eta
l S
pe
cif
ica
tio
ns
:F
ille
r M
eta
l S
pe
cif
ica
tio
n (
if r
eq
uir
ed
):W
eld
ing
Pro
ce
ss
(es
):
Qu
est
ion
#Jo
b A
ud
it Q
ue
stio
nR
ela
ted
WS
A Q
ue
stio
n #
Cu
sto
me
r o
r In
tern
al
Re
qu
ire
me
nt
Job
(S
ho
p)
Ord
er
or
Re
fere
nce
Do
cum
en
tatio
n
Re
qu
ire
me
nt
Act
ua
l Co
nd
itio
n
(Ob
ject
ive
Evi
de
nce
)P
ass
/ F
ail
/ N
/ A
6.1
7
Are
th
ere
do
cum
en
ted
re
act
ion
pla
ns
with
a
pp
rop
ria
te le
vels
of
con
tain
me
nt
to b
oth
o
ut
of
con
tro
l an
d o
ut
of
tole
ran
ce p
roce
ss
pa
ram
ete
rs a
nd
pro
vid
e d
ocu
me
nte
d
evi
de
nce
th
at
rea
ctio
n p
lan
s a
re f
ollo
we
d?
5.3
1.2
15
.61
.82
.7
6.1
8
Ho
w d
oe
s th
e o
rga
niz
atio
n h
an
dle
ch
an
ge
s to
pro
cess
co
ntr
ol p
ara
me
ters
aft
er
initi
al
cust
om
er
ap
pro
val a
nd
ho
w d
o y
ou
no
tify
you
r cu
sto
me
r?
1.6
5.4
1.2
21
.16
6.1
9A
re I
n-P
roce
ss a
nd
Fin
al T
est
s p
erf
orm
ed
at
est
ab
lish
ed
fre
qu
en
cie
s?
1.8
5.5
6.2
0A
re w
eld
qu
alit
y re
qu
ire
me
nts
cle
arl
y d
efin
ed
pe
r cu
sto
me
r sp
eci
fica
tion
s?
1.9
5.6
6.2
0.1
Te
st T
ype
:
Te
st M
eth
od
:
Te
st F
req
ue
ncy
an
d Q
ua
ntit
y:
Sp
eci
fica
tion
:
6.2
0.2
Te
st T
ype
:
Te
st M
eth
od
:
Te
st F
req
ue
ncy
an
d Q
ua
ntit
y:
Sp
eci
fica
tion
:
Ea
ch p
art
ma
y h
ave
on
e o
r m
ore
re
qu
ire
me
nts
de
term
ine
d b
y th
e w
eld
ing
sp
eci
fica
tion
. P
art
s m
ust
me
et
ea
ch r
eq
uir
em
en
t.
Lis
t re
qu
ire
me
nts
be
low
an
d v
alid
ate
.
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Se
cti
on
6 -
Jo
b A
ud
it
Jo
b I
de
nti
ty:
Cu
sto
me
r:S
ho
p O
rde
r N
um
be
r:P
art
Nu
mb
er:
Pa
rt D
es
cri
pti
on
:B
as
e M
eta
l S
pe
cif
ica
tio
ns
:F
ille
r M
eta
l S
pe
cif
ica
tio
n (
if r
eq
uir
ed
):W
eld
ing
Pro
ce
ss
(es
):
Qu
est
ion
#Jo
b A
ud
it Q
ue
stio
nR
ela
ted
WS
A Q
ue
stio
n #
Cu
sto
me
r o
r In
tern
al
Re
qu
ire
me
nt
Job
(S
ho
p)
Ord
er
or
Re
fere
nce
Do
cum
en
tatio
n
Re
qu
ire
me
nt
Act
ua
l Co
nd
itio
n
(Ob
ject
ive
Evi
de
nce
)P
ass
/ F
ail
/ N
/ A
6.2
0.3
Te
st T
ype
:
Te
st M
eth
od
:
Te
st F
req
ue
ncy
an
d Q
ua
ntit
y:
Sp
eci
fica
tion
:
6.2
0.4
Te
st T
ype
:
Te
st M
eth
od
:
Te
st F
req
ue
ncy
an
d Q
ua
ntit
y:
Sp
eci
fica
tion
:
- 30 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
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al Use
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
APPENDIX A – PROCESS TABLES
Process Table A: Arc Stud/Fastener Welding, Flux-Cored Arc Welding, Gas Metal Arc Welding, Submerged Arc Welding, Shielded Metal Arc Welding, Plasma Arc Welding, Gas Tungsten Arc Welding, and Gas Metal Arc Braze Welding ............................................................................................................. 32
Process Table B: Resistance Spot Welding, Projection Welding, Resistance Seam Welding, High-Frequency Seam Welding, Induction Seam Welding, Mash Seam Welding, and Flash Welding.............. 34
Process Table C: Nd YAG, CO2, DIODE, and Wire Fed......................................................................... 36
Process Table D: Inertia Friction Welding, Direct Drive Friction Welding, Friction Stir Welding, Flash Butt Welding, Resistance Butt Welding and Ultrasonic Welding ............................................................. 40
Propert
y of G
enera
l Moto
rs Corp
oratio
n
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al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
- 32 -
It
xx
em
#R
ela
ted
WS
A
Qu
es
tio
n #
Ca
teg
ory
/Pro
ce
ss
Ste
ps
Arc
Stu
d/
Fa
ste
ne
r W
eld
ing
(S
W)
Flu
x-
Co
red
Arc
W
eld
ing
(F
CA
W)
Ga
s M
eta
l A
rc
We
ldin
g
(GM
AW
)
Su
bm
erg
ed
A
rc W
eld
ing
(S
AW
)
Sh
ield
ed
M
eta
l A
rc
We
ldin
g
(SM
AW
)
Pla
sm
a A
rc
We
ldin
g
(PA
W)
Ga
s
Tu
ng
ste
n
Arc
W
eld
ing
(G
TA
W)
Ga
s M
eta
l A
rc B
raze
W
eld
ing
1.0
1.7
, 1
.8A
rc w
eld
ing
sp
ec
ific
es
se
nti
al
va
ria
ble
s w
hic
h s
ha
ll b
e
ad
dre
ss
ed
in
th
e F
ME
A,
co
ntr
ol
pla
n a
nd
we
ldin
g
pro
ce
du
res
A1
.1A
rc v
olta
ge
xx
xx
xx
A1
.2A
mp
era
ge
xx
xx
xx
xx
A1
.3C
urr
en
t ty
pe
(A
C/D
CE
N/D
CE
P)
xx
xx
xx
xx
A1
.4W
ire
fe
ed
sp
ee
dx
xx
x1
x1
x
A1
.5P
uls
e s
ett
ing
va
ria
ble
s sp
eci
fic t
o t
he
OE
M o
f th
e w
eld
ing
e
qu
ipm
en
t m
ust
be
do
cum
en
ted
an
d c
on
tro
lled
.x
x
A1
.6S
tud
gu
n/t
orc
h p
osi
tion
wo
rk a
ng
le,
tra
vel a
ng
le
xx
xx
xx
xx
A1
.7C
on
tact
tip
-to
-wo
rk d
ista
nce
xx
xx
A1
.8E
lect
rod
e-t
o-w
ork
dis
tan
c ex
x
A1
.9L
ift h
eig
ht
of
stu
dx
.10
Fa
ste
ne
r co
atin
g (
de
term
ine
s cu
rre
nt
typ
e)
x
.11
Plu
ng
e c
on
tro
l mo
de
fo
rce
or
po
sitio
nx
.12
Flu
x cl
ass
ifica
tion
an
d d
ep
thx
.13
Flu
x re
mo
val a
nd
re
cla
ima
tion
pla
nx
.14
Ga
s flo
w p
re-f
low
, p
ost
-flo
w,
rate
an
d t
ype
(s)
x2
x2
xx
.15
Ele
ctro
de
an
d/o
r fil
ler
me
tal t
ype
, d
iam
ete
r, a
nd
cl
ass
icifa
catio
nx
xx
xx
x1
x1
x
.16
Tra
vel s
pe
ed
xx
A1
A1
A1
A1
A1
xx
A1
A1
xx
x
.17
Ga
s n
ozz
le s
ize
an
d t
ype
x2
x2
xx
.18
Arc
sta
rtin
g p
ara
me
ters
xx
x
A1
xx
A1
xx
x
.19
Arc
en
d p
ara
me
ters
xx
xx
xx
l c
on
tro
l o
f v
ari
ab
les
giv
en
be
low
are
su
bo
rdin
ate
to
cu
sto
me
r s
pe
cif
ic r
eq
uir
em
en
ts.
cu
sto
me
r m
ay
ha
ve
ad
dit
ion
al
req
uir
em
en
ts,
e.g
., i
ns
pe
cti
on
te
sti
ng
, g
rea
ter
fre
qu
en
cie
s,
etc
. W
he
n p
erf
orm
ing
th
e j
ob
au
dit
, th
e a
ud
ito
r s
ha
ll v
eri
fy w
eld
ing
is
co
nfo
rmin
g
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
x
A1
Al
Th
eto D
aX
i.
in
dic
ate
s t
ha
t p
roc
ed
ure
sh
ou
ld b
e r
ev
iew
ed
an
d d
oc
um
en
ted
wh
en
ne
ce
ss
ary
.
PR
OC
ES
S T
AB
LE
A-
Arc
We
ldin
g P
roc
es
se
s
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 33 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Arc
Stu
d/
Fa
ste
ne
r W
eld
ing
(S
W)
Flu
x-
Co
red
Arc
W
eld
ing
(F
CA
W)
Ga
s M
eta
l A
rc
We
ldin
g
(GM
AW
)
Su
bm
erg
ed
A
rc W
eld
ing
(S
AW
)
Sh
ield
ed
M
eta
l A
rc
We
ldin
g
(SM
AW
)
Pla
sm
a A
rc
We
ldin
g
(PA
W)
Ga
s
Tu
ng
ste
n
Arc
W
eld
ing
(G
TA
W)
Ga
s M
eta
l A
rc B
raze
W
eld
ing
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
A-
Arc
We
ldin
g P
roc
es
se
s
A1
.20
Wir
e b
urn
ba
ck s
ett
ing
sx
xx
A1
.21
Plu
ng
e d
ep
thx
A1
.22
Arc
tim
ex
x3
x3
x3
x3
A1
.23
Fa
ste
ne
r g
eo
me
try
pe
r m
ate
ria
l typ
ex
A1
.24
No
zzle
cle
an
ing
an
d c
lea
ne
rs,
rep
lace
me
n
x
tA
1.2
5T
ip c
ha
ng
es
A1
.26
Wir
e li
ne
rs/c
on
du
its c
lea
nin
g a
nd
re
pla
cin
g
A1
.27
Dri
ve r
oll
cha
ng
es
A1
.28
Wir
e g
uid
e t
ub
e c
ha
ng
e
A1
.29
An
tisp
att
er
Ap
plic
atio
n (
spra
y/d
ip a
nd
eq
uip
me
nt)
A1
.30
Ele
ctro
de
an
d s
tud
co
llet
cha
ng
e
A1
.31
O r
ing
s in
ga
s sy
ste
m m
ain
ten
an
ce
A1
.32
Ga
s d
eliv
ery
an
d m
ixin
g s
yste
mx
2x
2x
x
A1
.33
Flu
x d
eliv
ery
sys
tem
s m
ain
ten
an
c
xx
e
A1
.34
Flu
x re
mo
val (
scre
en
s si
ze a
nd
ma
gn
etic
se
pa
rato
rs)
A1
.35
Ele
ctro
de
sh
arp
en
ing
A1
.36
Sla
g r
em
ova
lx
xx
A1
.37
Wir
e d
ere
ele
rs m
ain
ten
an
ce
A1
.38
Wir
e b
rake
ad
just
me
nt
A1
.39
Inte
gri
ty o
f g
rou
nd
sys
tem
x1 : P
roce
sse
s ca
n b
e u
sed
bo
th w
ith a
nd
with
ou
t fil
ler
me
tal.
x2 : T
he
se w
eld
ing
pro
cess
es
are
de
sig
na
ted
fo
r e
ithe
r g
as
shie
lde
d,
self
shie
lde
d o
r g
asl
ess
.
x3 : A
rc S
po
t w
eld
ing
ap
plic
act
ion
s o
nly
.
Wh
at
are
yo
ur
pro
ced
ure
s fo
r:
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Re
sis
tan
ce
S
po
t W
eld
ing
(RS
W)
Pro
jec
tio
n
We
ldin
g
(PW
)
Re
sis
tan
ce
S
ea
m
We
ldin
g
(RS
EW
)
Hig
h-
Fre
qu
en
cy
S
ea
m
We
ldin
g
(RS
EW
-HF
)
Ind
uc
tio
n
Se
am
W
eld
ing
(R
SE
W-I
)
Ma
sh
S
ea
m
We
ldin
g
(RS
EW
-M
S)
Fla
sh
W
eld
ing
* (F
W)
2.0
1.7
, 1
.8R
es
ista
nc
e w
eld
ing
sp
ec
ific
es
se
nti
al
va
ria
ble
s w
hic
h
sh
all
be
ad
dre
ss
ed
in
th
e F
ME
A,
co
ntr
ol
pla
n a
nd
we
ldin
g
pro
ce
du
res
B2
.1W
eld
fo
rce
XX
XX
B2
.2C
lam
p f
orc
Xe
B2
.3F
org
e f
orc
e
B2
.4F
org
e d
ela
y
B2
.5A
mp
era
ge
XX
XX
B2
.6V
olta
ge
XX
XX
B2
.7P
ow
er
B2
.8F
req
ue
ncy
XX
XX
XX
XB
2.9
Pu
lsa
tion
XX
XX
B2
.10
Sq
ue
eze
tim
e/c
ycle
sX
XX
X
B2
.11
We
ld t
ime
/cyc
les
XX
XX
B2
.12
Ho
ld t
ime
/cyc
les
XX
XX
XB
2.1
3Q
ue
nch
tim
e/c
ycle
X
s
B2
.14
Te
mp
er
time
B2
.15
Co
ol t
ime
/cyc
les
XX
XX
B2
.16
Up
slo
pe
tim
e/c
ycle
sX
XX
XX
XX
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s
co
nfo
rmin
g t
o t
he
cu
sto
me
r's
re
qu
ire
me
nts
.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
B-
Re
sis
tan
ce
We
ldin
g P
roc
es
se
s
- 34 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 35 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Re
sis
tan
ce
S
po
t W
eld
ing
(RS
W)
Pro
jec
tio
n
We
ldin
g
(PW
)
Re
sis
tan
ce
S
ea
m
We
ldin
g
(RS
EW
)
Hig
h-
Fre
qu
en
cy
S
ea
m
We
ldin
g
(RS
EW
-HF
)
Ind
uc
tio
n
Se
am
W
eld
ing
(R
SE
W-I
)
Ma
sh
S
ea
m
We
ldin
g
(RS
EW
-M
S)
Fla
sh
W
eld
ing
* (F
W)
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s
co
nfo
rmin
g t
o t
he
cu
sto
me
r's
re
qu
ire
me
nts
.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
B-
Re
sis
tan
ce
We
ldin
g P
roc
es
se
s
B2
.17
Ste
pp
er
pro
gra
ms
X
B2
.18
Tip
/ele
ctro
de
/wh
ee
l dre
ssin
gX
XX
XX
B2
.19
We
ld t
rave
l sp
ee
dX
XX
XB
2.2
0A
de
qu
ate
ele
ctro
de
fo
llow
up
in w
eld
fo
rce
/ d
ista
nce
XX
XB
2.2
1S
yste
m c
oo
ling
-tra
nsf
orm
ers
, e
lect
rod
es,
etc
.X
XX
XX
X
B2
.22
Tip
/ele
ctro
de
/wh
ee
l/co
il ch
an
ge
fre
qu
en
cyX
XX
XX
XB
2.2
3T
ip/e
lect
rod
e/w
he
el/c
oil
alig
nm
en
tX
XX
XX
XB
2.2
4E
lect
rod
e s
ele
ctio
n/t
ype
(m
ate
ria
l typ
e e
tc.
X X X X
)
B2
.25
Ele
ctro
de
ge
om
etr
yB
2.2
6In
du
ctio
n c
oil
ge
om
etr
yB
2.2
7S
eco
nd
ary
loo
p e
lect
rica
l co
nd
uct
ors
(ca
ble
s, le
af
shu
nts
, e
tc.)
an
d m
ech
an
ica
l jo
ints
ma
inte
na
nce
B
2.2
8P
roje
ctio
n w
eld
ge
om
etr
y a
nd
siz
e
*Fla
sh W
eld
ing
is a
So
lid S
tate
pro
cess
, h
ow
eve
r, t
he
pro
cess
co
ntr
ols
mo
st r
ese
mb
le a
re
sist
an
ce w
eld
pro
cess
.R
efe
r to
Ta
ble
D fo
r o
the
r re
qu
ire
me
nts
on
Fla
sh W
eld
ing
Wh
at
are
yo
ur
pro
ced
ure
s fo
r:
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s N
d Y
AG
(L
BW
)C
O2
(L
BW
)D
IOD
E
(LB
W)
Wit
h W
ire
F
ee
d
Sy
ste
m
3.0
1.7
, 1
.8 W
eld
ing
sp
ec
ific
es
se
nti
al
va
ria
ble
s w
hic
h s
ha
ll b
e
ad
dre
ss
ed
in
th
e F
ME
A,
co
ntr
ol
pla
n a
nd
we
ldin
g
pro
ce
du
res
Eq
uip
me
nt
C3
.1B
ea
m q
ua
lity
XX
XX
C3
.2O
ptic
cle
an
line
ssX
XX
XC
3.3
Cro
ss je
t o
r la
ser
knife
XX
XX
C3
.4B
ea
m c
on
figu
ratio
n (
split
, si
ng
le)
XX
XX
C3
.5F
oca
l le
ng
thX
XX
XC
3.6
Be
am
sp
ot
size
XX
XX
C3
.7G
as
tub
e a
ng
le/a
rra
ng
em
en
tX
XX
XC
3.8
Op
tics
pu
rge
ga
s (f
low
an
d q
ua
lity)
XX
C3
.9M
irro
r cl
ea
nlin
ess
XX
XC
3.1
0M
irro
r d
eg
rad
atio
nX
XX
C3
.11
Be
am
sh
ari
ng
XX
XX
C3
.12
Sp
lit b
ea
mX
XX
XC
3.1
3T
ip c
ha
ng
es
XC
3.1
4O
rin
gs
in g
as
syst
em
X
PR
OC
ES
S T
AB
LE
C-
La
se
r W
eld
ing
Pro
ce
ss
es
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
- 36 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 37 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s N
d Y
AG
(L
BW
)C
O2
(L
BW
)D
IOD
E
(LB
W)
Wit
h W
ire
F
ee
d
Sy
ste
m
PR
OC
ES
S T
AB
LE
C-
La
se
r W
eld
ing
Pro
ce
ss
es
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
C3
.15
Ga
s n
ozz
leX
C3
.16
To
rch
an
gle
sX
C3
.17
Ch
ille
rs (
inte
rna
l - e
xte
rna
l)X
XX
XC
3.1
8 -
Flo
w r
ate
XX
XX
C3
.19
- W
ate
r q
ua
lity
XX
XX
C3
.20
- T
ype
of
coo
lan
tX
XX
XC
3.2
1 -
Ad
diti
ve c
on
cen
tra
tion
XX
XX
C3
.22
- T
em
pe
ratu
re c
on
tro
l (ra
te o
f ch
an
ge
an
d r
an
ge
)X
XX
XC
3.2
3W
ire
fe
ed
sys
tem
XC
3.2
4 -
Wir
e f
ee
d s
pe
ed
XC
3.2
5 -
Wir
e li
ne
rs/c
on
du
its c
lea
nin
g a
nd
re
pla
cin
gX
C3
.26
- D
rive
ro
ll ch
an
ge
sX
C3
.27
- W
ire
gu
ide
tu
be
XC
3.2
8 -
Wir
e d
ere
ale
rsX
C3
.29
- W
ire
bra
ke a
dju
stm
en
tX
C3
.30
- W
ire
cle
an
ers
/wip
ers
XC
3.3
1 -
Co
nta
ct t
ip t
o w
ork
dis
tan
ceX
C3
.32
- W
ire
po
sitio
n t
o la
ser
foca
l po
int
X
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s N
d Y
AG
(L
BW
)C
O2
(L
BW
)D
IOD
E
(LB
W)
Wit
h W
ire
F
ee
d
Sy
ste
m
PR
OC
ES
S T
AB
LE
C-
La
se
r W
eld
ing
Pro
ce
ss
es
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
Be
am
De
liv
ery
C3
.33
Dir
ect
XX
C3
.34
Fib
er
XX
XC
3.3
5 -
Fib
er
dia
me
ter
XX
C3
.36
- F
ibe
r le
ng
ths
XX
C3
.37
- B
en
d r
ad
ius
XX
C3
.38
- C
on
diti
on
of
fibe
rX
X
C3
.39
- F
ibe
r e
nd
s (c
on
diti
on
of
fibe
r e
nd
s)X
X
C3
.40
- F
ibe
r e
nd
co
olin
gX
X
C3
.41
Mir
ror
XX
C3
.42
- P
ow
er
loss
th
ou
gh
th
e d
eliv
ery
sys
tem
XX
C3
.43
- A
lign
me
nt
XX
C3
.44
- C
lea
nlin
ess
XX
C3
.45
- C
oa
ting
s o
f m
irro
rX
XC
3.4
6 -
Mir
ror
typ
eX
XC
3.4
7 -
Op
tic a
nd
mir
ror
coo
ling
XX
Pro
ce
ss
Va
ria
ble
sC
3.4
8S
hie
ldin
g g
as
typ
e -
flo
w r
ate
XX
XX
C3
.49
We
ld t
rave
l sp
ee
d c
on
tro
l (ra
te o
f ch
an
ge
, a
nd
ve
loci
ty
con
tro
l)X
X
XX
C3
.50
Po
we
r O
utp
ut
Co
ntr
ol
XX
XX
C3
.51
Po
we
r ra
mp
ing
/pro
gra
m (
sta
rt,
we
ld,
en
d)
XX
XX
C3
.52
Po
we
r a
t th
e w
ork
pie
ceX
XX
X X X X X X X
- 38 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 39 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s N
d Y
AG
(L
BW
)C
O2
(L
BW
)D
IOD
E
(LB
W)
Wit
h W
ire
F
ee
d
Sy
ste
m
PR
OC
ES
S T
AB
LE
C-
La
se
r W
eld
ing
Pro
ce
ss
es
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
C3
.53
Off
set
of
be
am
to
join
tX
XX
XC
3.5
4C
on
tinu
ou
s w
ave
XX
XX
C3
.55
Pu
lsa
tion
XX
XX
C3
.56
An
gle
of
Inci
de
nce
XX
XX
C3
.57
Fo
cus
po
int
XX
XX
C3
.58
Dir
ect
ion
of
we
ldin
g (
tra
ilin
g o
r le
ad
)X
XX
XC
3.5
9B
ea
m q
ua
lity
bu
rn-i
nX
XX
XC
3.6
0P
ow
er
ou
tpu
t co
ntr
ol c
alib
ratio
nX
XX
XC
3.6
1P
lasm
a s
up
pre
ssio
nX
XC
3.6
2 -
Mo
nito
rin
g B
ack
sca
tte
r fo
r co
ntr
ol p
roce
ss
Fix
ture
s/P
art
C3
.63
- S
tab
ility
an
d/o
r vi
bra
tion
iso
latio
nX
XX
XC
3.6
4 -
Art
icu
latio
n s
yste
m (
smo
oth
ne
ss o
f m
otio
n a
nd
acc
ura
cy)
XX
XX
C3
.65
Pa
rt f
it u
pC
3.6
6S
ea
m t
rack
ing
C3
.67
Ed
ge
co
nd
itio
nC
3.6
8C
oa
ting
s
Wh
at
are
yo
ur
pro
ced
ure
s fo
r co
ntr
olli
ng
:
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Ine
rtia
F
ric
tio
n
We
ldin
g
(FR
W-I
)
Dir
ec
t D
riv
e
Fri
cti
on
W
eld
ing
(F
RW
-DD
)
Fri
cti
on
S
tir
We
ldin
g
(FS
W)
Fla
sh
Bu
tt
We
ldin
g
(FW
)
Re
sis
tan
ce
B
utt
W
eld
ing
(U
W)
Ult
ras
on
ic
We
ldin
g
4.0
1.7
, 1
.8 W
eld
ing
sp
ec
ific
es
se
nti
al
va
ria
ble
s w
hic
h s
ha
ll b
e
ad
dre
ss
ed
in
th
e F
ME
A,
co
ntr
ol
pla
n a
nd
we
ldin
g
pro
ce
du
res
D4
.1T
ole
ran
ces
on
axi
al a
lign
me
nt
XX
XD
4.2
Fa
yin
g s
urf
ace
are
aX
XX
D4
.3F
ayi
ng
su
rfa
ce c
lea
nlin
ess
XX
XD
4.4
Initi
al s
pin
da
l sp
ee
dX
XX
D4
.5W
eld
ing
sp
ind
al s
pe
ed
XD
4.6
Sp
ind
al t
orq
ue
- t
o n
ot
da
ma
ge
eq
uip
me
nt
XX
XD
4.7
Fly
wh
ee
ls;
tota
l mo
me
nt
of
ine
rtia
X
D4
.8S
pin
dle
cla
mp
pre
ssu
reX
XX
D4
.9F
ixtu
re c
lam
p p
ress
ure
XX
XD
4.1
0P
art
stic
kou
t X
X
Pre
he
at
(Fir
st
fric
tio
n p
ha
se
) if
ne
ed
ed
D4
.11
-Pro
ject
ion
on
fa
yin
g s
urf
ace
X1
X1
D4
.12
-Pre
he
at
forc
eX
1X
1
D4
.13
-Pre
he
at
time
or
RP
MX
1X
1
D4
.14
Pre
he
at
bu
rno
ff le
ng
th-a
mo
un
t o
f d
ime
nsi
on
loss
du
rin
g
pre
he
at
X1
XX
We
ld H
ea
t (S
ec
on
d f
ric
tio
n p
ha
se
)
D4
.15
-Fri
ctio
n w
eld
fo
rce
XX
D4
.16
-Fri
ctio
n s
pe
ed
at
wh
ich
fo
rgin
g b
eg
ins
XX
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
D -
So
lid
Sta
te W
eld
ing
Pro
ce
ss
es
- 40 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Ine
rtia
F
ric
tio
n
We
ldin
g
(FR
W-I
)
Dir
ec
t D
riv
e
Fri
cti
on
W
eld
ing
(F
RW
-DD
)
Fri
cti
on
S
tir
We
ldin
g
(FS
W)
Fla
sh
Bu
tt
We
ldin
g
(FW
)
Re
sis
tan
ce
B
utt
W
eld
ing
(U
W)
Ult
ras
on
ic
We
ldin
g
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
D -
So
lid
Sta
te W
eld
ing
Pro
ce
ss
es
Fo
rgin
g S
tag
eD
4.1
7-F
org
ing
sp
ee
dX
XD
4.1
8-F
org
e f
orc
eX
XD
4.1
9-F
org
e t
ime
XD
4.2
0-F
org
e le
ng
th if
lim
ited
up
set
is u
sed
XD
4.2
1-F
org
e d
ela
yX
D4
.22
-Up
set
dis
tan
ceX
D4
.23
-Up
set
rem
ova
l / m
an
ag
em
en
tX
XD
4.2
4-U
pse
t h
old
tim
eX
XD
4.2
5-U
pse
t ra
teX
XD
4.2
6-F
rict
ion
up
set
dis
tan
ce a
nd
tim
eX
D4
.27
Bra
ke s
ett
ing
or
sto
pp
ing
tim
e d
ime
nsi
on
s a
nd
to
lere
nce
sX
D4
.28
Bra
ke f
orc
eX
D4
.29
Bra
ke d
ela
y p
rio
r to
up
set
XD
4.3
0F
ina
l po
sitio
nX
D4
.31
Po
stw
eld
he
at
tre
atm
en
t if
ne
ed
ed
ba
sed
on
ma
teri
als
join
ed
D4
.32
Pro
tect
ive
atm
osp
he
re if
ne
cess
ary
fo
r th
e b
ase
ma
teri
al
D4
.33
To
tal b
urn
off
-am
ou
nt
of
dim
en
sio
n lo
ss d
uri
ng
to
tal p
roce
ssX
XX
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Ine
rtia
F
ric
tio
n
We
ldin
g
(FR
W-I
)
Dir
ec
t D
riv
e
Fri
cti
on
W
eld
ing
(F
RW
-DD
)
Fri
cti
on
S
tir
We
ldin
g
(FS
W)
Fla
sh
Bu
tt
We
ldin
g
(FW
)
Re
sis
tan
ce
B
utt
W
eld
ing
(U
W)
Ult
ras
on
ic
We
ldin
g
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
D -
So
lid
Sta
te W
eld
ing
Pro
ce
ss
es
FS
WD
4.3
4P
rim
ary
co
ntr
ol (
po
sitio
n o
r fo
rce
)X
D4
.35
To
ol t
o w
eld
join
t a
lign
me
nt
du
rin
g le
ng
th o
f tr
ave
lX
To
ol
D4
.36
-Pin
to
sh
ou
lde
r ra
tioX
D4
.37
-Pin
len
gth
XD
4.3
8-I
ncl
ud
ed
an
gle
fo
r p
inX
D4
.39
-In
clu
de
d a
ng
le f
or
sho
uld
er
XD
4.4
0-T
hre
ad
on
pin
su
rfa
ceX
D4
.41
-Pin
ma
teri
al
X
Plu
ng
e P
rac
tic
e
D4
.42
-Sp
ee
d o
f p
lun
ge
XD
4.4
3-S
pin
da
l sp
ee
d d
uri
ng
plu
ng
eX
D4
.44
-Pre
he
at
dw
ell
time
aft
er
plu
ng
eX
D4
.45
-Plu
ng
e f
orc
eX
We
ld
D4
.46
-We
ld f
orc
eX
D4
.47
-Tra
vel s
pe
ed
XD
4.4
8-T
oo
l tilt
an
gle
XD
4.4
9-W
eld
sp
ind
al s
pe
ed
X
We
ld t
erm
ina
tio
nD
4.5
0-E
xit
mo
tion
of
too
l su
ch a
s til
t a
ng
le r
ota
tion
XD
4.5
1-S
pin
da
l sp
ee
d a
t to
ol e
xtra
ctio
nX
D4
.52
-Dw
ell
at
en
d o
f tr
ave
lX
- 42 -
Propert
y of G
enera
l Moto
rs Corp
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n
Intern
al Use
Only
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Ine
rtia
F
ric
tio
n
We
ldin
g
(FR
W-I
)
Dir
ec
t D
riv
e
Fri
cti
on
W
eld
ing
(F
RW
-DD
)
Fri
cti
on
S
tir
We
ldin
g
(FS
W)
Fla
sh
Bu
tt
We
ldin
g
(FW
)
Re
sis
tan
ce
B
utt
W
eld
ing
(U
W)
Ult
ras
on
ic
We
ldin
g
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
D -
So
lid
Sta
te W
eld
ing
Pro
ce
ss
es
FB
W R
BW
D4
.53
Ele
ctro
de
de
sig
n-e
limin
ate
die
bu
rns
XX
D4
.54
Ele
ctro
de
/Die
cle
an
line
ssX
XD
4.5
5E
lect
rod
e/D
ie c
lam
pin
g p
ress
ure
XX
D4
.56
Pa
rt c
lea
nlin
ess
an
d s
cale
re
mo
val
XX
D4
.57
Pa
rt a
lign
me
nt
XX
D4
.58
Join
t g
eo
me
try
pre
po
ratio
nX
XD
4.5
9In
itia
l ma
rtia
l stic
kou
t o
r e
xte
nsi
on
be
yon
d e
lect
rod
es
XX
Pre
he
at
D4
.60
-Pre
he
at
forc
eX
XD
4.6
1-T
ap
se
lect
ion
XX
D4
.62
-Pe
rce
nt
he
at
XX
D4
.63
-Off
tim
e d
uri
ng
initi
al d
ie o
pe
nin
gX
Init
ial
Fla
sh
ing
D
4.6
4-I
niti
al d
ie o
pe
nin
gX
D4
.65
-In
itia
l fla
shin
g r
ate
XD
4.6
6-T
ype
of
pla
tte
n m
ove
me
nt
(lin
ea
r o
r p
ara
bo
lic)
XD
4.6
7-V
olta
ge
XD
4.6
8-I
niti
al f
lash
ing
dis
tan
ce o
r tim
eX
D4
.69
-Pe
rce
nt
he
at
XD
4.7
0-T
ap
se
lect
ion
X
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Ine
rtia
F
ric
tio
n
We
ldin
g
(FR
W-I
)
Dir
ec
t D
riv
e
Fri
cti
on
W
eld
ing
(F
RW
-DD
)
Fri
cti
on
S
tir
We
ldin
g
(FS
W)
Fla
sh
Bu
tt
We
ldin
g
(FW
)
Re
sis
tan
ce
B
utt
W
eld
ing
(U
W)
Ult
ras
on
ic
We
ldin
g
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
D -
So
lid
Sta
te W
eld
ing
Pro
ce
ss
es
Fla
sh
ing
D4
.71
-Fla
shin
g r
ate
XD
4.7
2-T
ype
of
pla
tte
n m
ove
me
nt
(lin
ea
r o
r p
ara
bo
lic)
XD
4.7
3-V
olta
ge
XD
4.7
4-F
lash
ing
dis
tan
ce o
r tim
eX
D4
.75
-Pe
rce
nt
he
at
XD
4.7
6-T
ap
se
lect
ion
X
We
ld S
tag
e 1
D4
.77
-Pe
rce
nt
he
at
XD
4.7
8-T
ap
se
lect
ion
vo
ltag
eX
D4
.79
-Fo
rce
XD
4.8
0-P
uls
atio
n (
on
, o
ff a
nd
nu
mb
er
of
pu
lse
s)X
D4
.81
-Off
tim
e b
efo
re s
tag
e c
ha
ng
eX
We
ld S
tag
e 2
(c
an
be
mu
ltip
le s
tag
es
wit
h d
iffe
ren
t p
ara
me
ters
)D
4.8
2-P
erc
en
t h
ea
tX
D4
.83
-Ta
p s
ele
ctio
n v
olta
ge
XD
4.8
4-F
orc
eX
D4
.85
-Pu
lsa
tion
(o
n,
off
an
d n
um
be
r o
f p
uls
es)
X
- 44 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
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CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Ine
rtia
F
ric
tio
n
We
ldin
g
(FR
W-I
)
Dir
ec
t D
riv
e
Fri
cti
on
W
eld
ing
(F
RW
-DD
)
Fri
cti
on
S
tir
We
ldin
g
(FS
W)
Fla
sh
Bu
tt
We
ldin
g
(FW
)
Re
sis
tan
ce
B
utt
W
eld
ing
(U
W)
Ult
ras
on
ic
We
ldin
g
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
D -
So
lid
Sta
te W
eld
ing
Pro
ce
ss
es
Fo
rge
/Up
se
tD
4.8
6-F
org
e r
ate
XX
D4
.87
-Fo
rge
fo
rce
XX
D4
.88
-Fo
rge
dis
tan
ce /
to
tal u
pse
tX
XD
4.8
9-U
pse
t tim
eX
XD
4.9
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pse
t cu
rre
nt
XX
D4
.91
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ge
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t o
ffX
D4
.92
-Fla
shin
g r
em
ova
l / m
an
ag
em
en
tX
X
Po
st
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ld h
ea
t tr
ea
tme
nt
if n
ee
de
dD
4.9
3-H
ea
t tr
ea
tme
nt
cla
mp
ing
dis
tan
ceD
4.9
4-Q
ue
nch
tim
eD
4.9
5-T
ap
se
lect
ion
D4
.96
-Pre
cen
t h
ea
tD
4.9
7-T
em
pe
r tim
eD
4.9
8F
ina
l die
op
en
ing
XX
Ult
ras
on
ic M
eta
l w
eld
D4
.99
Ta
p s
ele
ctio
n /
d
esi
gn
of
rib
bo
n s
tru
ctu
reD
4.1
00
Fre
qu
en
cy o
f p
ow
er
sup
ply
fo
r a
pp
lica
tion
(4
0/3
0/2
0kH
z)D
4.1
01
Fix
ture
& p
art
de
sig
n w
ith m
ax
dim
en
sio
n d
evi
atio
n a
nd
ma
teri
al s
pe
cs
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Ine
rtia
F
ric
tio
n
We
ldin
g
(FR
W-I
)
Dir
ec
t D
riv
e
Fri
cti
on
W
eld
ing
(F
RW
-DD
)
Fri
cti
on
S
tir
We
ldin
g
(FS
W)
Fla
sh
Bu
tt
We
ldin
g
(FW
)
Re
sis
tan
ce
B
utt
W
eld
ing
(U
W)
Ult
ras
on
ic
We
ldin
g
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
D -
So
lid
Sta
te W
eld
ing
Pro
ce
ss
es
Up
se
t a
nd
Mo
nit
ori
ng
(w
ind
ow
ing
)D
4.1
02
We
ldin
g-E
ne
rgy
XD
4.1
03
We
ldin
g-T
ime
XD
4.1
04
We
ldin
g-A
mp
litu
de
XD
4.1
05
We
ldin
g-F
orc
eX
D4
.10
6W
eld
ing
-Cu
rre
nt
XD
4.1
07
We
ldin
g p
re H
eig
ht
an
d t
rave
l (co
mp
act
ion
)X
D4
.10
8E
ne
rgy
with
he
igh
t co
mp
en
satio
nX
D4
.10
9W
eld
He
ad
Co
olin
gD
4.1
10
En
viro
nm
en
tal c
on
diti
on
s co
ntr
ol (
i.e.,
te
mp
era
ture
, h
um
idity
, d
ust
, e
tc.)
D4
.11
1T
AP
/Die
cle
an
line
ssD
4.1
12
TA
P/D
ie c
lam
pin
g p
ress
ure
D4
.11
3P
art
cle
an
line
ss a
nd
sca
le r
em
ova
lD
4.1
14
Pa
rt a
lign
me
nt
x1:
If r
eq
uir
ed
to
ach
ieve
he
at
ba
lan
ce.
Exa
mp
le t
hin
pa
rt t
o t
hic
k p
art
or
vari
ou
s h
ard
ne
sse
s.
- 46 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 47 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
Ite
m #
Re
late
d W
SA
Q
ue
sti
on
#C
ate
go
ry/P
roc
es
s S
tep
s
Ine
rtia
F
ric
tio
n
We
ldin
g
(FR
W-I
)
Dir
ec
t D
riv
e
Fri
cti
on
W
eld
ing
(F
RW
-DD
)
Fri
cti
on
S
tir
We
ldin
g
(FS
W)
Fla
sh
Bu
tt
We
ldin
g
(FW
)
Re
sis
tan
ce
B
utt
We
ldin
g
(UW
)
Ult
ras
on
ic
We
ldin
g
All
co
ntr
ol
of
va
ria
ble
s g
ive
n b
elo
w a
re s
ub
ord
ina
te t
o c
us
tom
er
sp
ec
ific
re
qu
ire
me
nts
.
Th
e c
us
tom
er
ma
y h
av
e a
dd
itio
na
l re
qu
ire
me
nts
, e
.g.,
in
sp
ec
tio
n t
es
tin
g,
gre
ate
r fr
eq
ue
nc
ies
, e
tc.
Wh
en
pe
rfo
rmin
g t
he
jo
b a
ud
it,
the
au
dit
or
sh
all
ve
rify
we
ldin
g i
s c
on
form
ing
to
th
e c
us
tom
er'
s r
eq
uir
em
en
ts.
Da
sh
es
be
low
in
dic
ate
"n
ot
ap
pli
ca
ble
".
X i
nd
ica
tes
an
es
se
nti
al
va
ria
ble
wh
ich
sh
all
be
do
cu
me
nte
d a
nd
co
ntr
oll
ed
. i
nd
ica
tes
th
at
pro
ce
du
re s
ho
uld
be
re
vie
we
d a
nd
do
cu
me
nte
d w
he
n n
ec
es
sa
ry.
PR
OC
ES
S T
AB
LE
D -
So
lid
Sta
te W
eld
ing
Pro
ce
ss
es
Up
se
t a
nd
Mo
nit
ori
ng
(w
ind
ow
ing
)D
4.1
13
We
ldin
g-E
ne
rgy
XD
4.1
14
We
ldin
g-T
ime
XD
4.1
15
We
ldin
g-A
mp
litu
de
XD
4.1
16
We
ldin
g-F
orc
eX
D4
.11
7W
eld
ing
-Cu
rre
nt
XD
4.1
18
We
ldin
g p
re H
eig
ht
an
d t
rave
l (co
mp
act
ion
)X
D4
.11
9E
ne
rgy
with
he
igh
t co
mp
en
satio
nX
D4
.12
0W
eld
He
ad
Co
olin
gD
4.1
21
En
viro
nm
en
tal c
on
diti
on
s co
ntr
ol (
i.e.,
te
mp
era
ture
, h
um
idity
, d
ust
, e
tc.)
D4
.12
2T
AP
/Die
cle
an
line
ssD
4.1
23
TA
P/D
ie c
lam
pin
g p
ress
ure
D4
.12
4P
art
cle
an
line
ss a
nd
sca
le r
em
ova
lD
4.1
25
Pa
rt a
lign
me
nt
x1 : If
re
qu
ire
d t
o a
chie
ve h
ea
t b
ala
nce
. E
xam
ple
th
in p
art
to
th
ick
pa
rt o
r va
rio
us
ha
rdn
ess
es.
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
- 48 -
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 49 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
GLOSSARY
See also AWS A3.0: welding terms and definitions
AIAG – Automotive Industry Action Group
AWS American Welding Society
ANSI American National Standard Institute
Capability – The total range of inherent variation in a stable process.
Control Plans – Written descriptions of the system for controlling processes for production of parts or bulk materials. Control Plans are written by organizations to address the important characteristics and engineering requirements of the product. Each part must have a Control Plan, but in many cases, “family” Control Plans can apply to a number of parts produced using a common process.
Critical Spare Parts List – A list of service parts critical for the operation of equipment. Extended delay in obtaining spare parts would result in unacceptable delays in the welding operation.
Cross-Functional 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, etc.
Inter-Lock – A method of preventing missed steps within the operations by putting controls on how an operation can be performed in order to force the correct completion of the operation.
Nonconforming Product – Product that does not conform to the customer requirements.
Process Tables – Tables in the WSA that list the required process controls for the welding processes covered. These tables contain minimum requirements.
Reprocessing – Any process that is performed on nonconforming product so that it will meet the specified requirements.
Responsibility Matrix – A responsibility matrix defines the designated personnel for all key functions. This matrix includes the primary and secondary designees.
Robust – A stable predictive outcome regardless of variation within operating window; able to withstand its environment, not prone to failure.
SAE International – Society of Automotive Engineers International
Shop Traveler – A document usually created in the receiving department for each batch or lot of parts received. The document defines the process routing of the parts.
Special Characteristics – are product characteristics or manufacturing process parameters which can affect safety or compliance with regulations, fit, function, performance or subsequent processing of product. Refer to customer-specific requirements.
WSA - Welding System Assessment
Propert
y of G
enera
l Moto
rs Corp
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n
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al Use
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CQI-15 Special Process: Welding System Assessment Version 1 Issued 3/10
- 50 -
Work Instructions – Instructions that describe work conducted in one function in a company, e.g., setup, inspection, welding operation, process parameter tolerances, etc. The term “work instructions” is synonymous with the term “job instructions.”
Propert
y of G
enera
l Moto
rs Corp
oratio
n
Intern
al Use
Only
- 51 -
CQI-15Special Process: Welding System Assessment
Version 1 Issued 3/10
MAINTENANCE REQUEST FORM
Name of Submitter: Date:
Company:
Company Address:
Phone: Fax: E-mail:
MAINTENANCE REQUEST
Page Number of Change:
Document Currently Reads:
Recommended Changes/Should Read:
Reason for Change (Use additional sheets if necessary):
Signature of Submitter:
DISPOSITION (AIAG USE ONLY)
Manager’s Recommendation:
Final Disposition:
Comments:
Note: Complete form and return to the AIAG Publication Specialist for consideration. Automotive Industry Action Group • 26200 Lahser Road • Suite 200 • Southfield, MI 48033
Telephone: (248) 358-3570 • Fax: (248) 358-3253 Web: www.aiag.org
Propert
y of G
enera
l Moto
rs Corp
oratio
n
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al Use
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