cal-23 Special Process: Molding System Assessment 1st Edition » Insight » Expertise » Results The Catalyst for Peak Performance | AIAGecAIAG gatas Special Process: Molding System Assessment “The Catlyt for Pook Perforce” ‘Version 1, Issued 03/2014 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 quaity, 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 fulltime 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, CADICAM, EDlielectronic commerce, continuous quality improvement, heaith 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 @ consensus of those substantaly concemed wit is scope and provisions. An ‘AIAG publication i intended as a guido (o ald tho manufacturer, the consumer and the general public. The ‘existence of an AIAG publication does notin any respect preclude anyone from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the pubiction. (CAUTIONARY NOTICE AIAG publications are subjct fo periods reviw and usors are cautioned (o obain the latest edons. MAINTENANCE PROCEDURE Recognizing that this AIAG publication may not cover all crcumstances, AIAG has established a maintonance procedure. Please referto the Manianance Request For a the back of his document to submit a request. Published by: ‘Automotive Industry Action Group 126200 Lahser Road, Suite 200 ‘Southfield, Michigan 48033 Phone: (248) 358-3570 » Fax: (248) 358-3253 APPROVAL STATUS The AIAG Qualty Steering Commitee and designated stakeholders approved his document for publication in March 2044 AIAG COPYRIGHT AND TRADEMARK NOTICE: The contents of al published materials ar copyrighted by the Automotive Industy Action Group unloss otherwise indicated. Copyrights net claimed as fo any part of an original work proparod by a U.S. o state govornmant ofcer or amployeo as part of te ‘person's offeial duties. Al ights are preserved by AIAG, nd content may not be altered or disseminated, published, or Vansfered ln pat of such content. The information isnot o be sold in part or whole fo anyone within your organization orto another company. Copyright intingoment isa violation of foderal aw subject to criminal and civil penalies. AIAG and the Automotive Industy Action (Group are registered service marke ofthe Automotive dusty Action Group, © 2014 Automotive Industry Action Group Sane: 978 1-60584 209 7cal-23 Soest oct deg Syston Assesaman AIAG» Version 1 Issued 03/2014 “The Catalyst for Peak Perfoeranca™ FOREWORD Automotive Industry Action Group (AIAG) committees are made up of volunteers from member companies in the automotive industry, This edition is a compilation of best practices developed collaboratively by industry experts from OEMs, Tier | suppliers, and molding suppliers and represents an ideal practice. In the Molding System Assessment, the words “shall”, “requirement”, and “should” indicate a requirement or recommendation for purposes of this self-assessment only. ‘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 and industry experts for review and consensus approval. Publication of the documents requires approval by the Quality Steering Committee.AIAG caves ‘Special Process: Molding System Assessment “Tho Catalyst for PoskPortorrares™ Version 1, Isued 03/2014 ACKNOWLEDGEMENTS ‘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. Ken Campbell Ventra Plastics Kevin Keller Robert Bosch LLC Vimi Khanna Chrysler Group LLC Ed Luibrand Chrysler Group LLC Donita Morgan Toyota Motor Engineering, NA David Post Delphi Corporation Carey Price ARE. Accessories LLC Daniel Simoes Ford Motor Company Brazil David Toutant Robert Bosch LLC Daniel Williams General Motors Company Larry Xu Ford Motor Company Ashley Claus AIAG Karen Whitmore AIAGVersion 1, sued 0972014 Tho Cotaat or Peak ortormana TABLE OF CONTENTS ‘ABOUT AIAG FOREWORD ‘TABLE OF CONTENTS. INTRODUCTION .. Genera, PROCESS APPROACH ‘MOLDING SvsTEM ASSESSMENT GOALS ASSESSMENT PROCESS... ASSESSOR QUALIFICATIONS. (OTHER Requitemenrs. 1 SCOPE L.A GENERAL ssn 1.2 APPLICATION... 2 THE MOLDING SYSTEM ASSESSMENT PROCEDURE .. 3 SPECIAL PROCESS: MOLDING ASSESSMENT. [APPENDIX A ~ PROCESS TABLES. Process Table A: Injection MOlBINg senses vo rene 34 Process Table B: Blow Molding 39 Process Table C: Vacuum Forming 44 Process Table D: Compression Molding 47 Process Table E: Transfer Molding Thermoset Matera)... 50 Process Table F Extrusion. zi Process Table G: EQUIPMENT Process Table H: Part Inspection and Testing, GLOSSARY...AIAG gauzs ee ‘The Catlyet fx Peak Parfoareca™ Version 1, Issued 03/2014 INTRODUCTION General ‘The work of preparing CQI-23: Special Process: Molding System Assessment was carried out through the AIAG Molding Work Group. These molding requirements are complementary to customer and product standards. ‘The Molding System Assessment 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 Molding System Assessment can also be used between an organization and its suppliers. In the Molding System Assessment, the word “shall” indicates a requirement for purposes of this self assessment. Failure to meet the requirements results in an assessment that is either “Not Satisfactory” of “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 Molding System Assessment supports the automotive process approach as described in ISO/TS 16949, Molding System Assessment Goals The goal of the Molding System Assessment is the development of a molding management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain. ‘The Molding System Assessment, coupled with an internationally recognized quality management system and applicable customer-specific requirements, defines the fundamental requirements for molding ‘management systems. ‘The Molding System Assessment is intended to provide a common approach to a molding management system for automotive production and service part organizations, Assessment Process Ongoing assessments shall be conducted annually, unless otherwise specified by the customer, to reexamine the continuing compliance with the Molding System Assessment. Each assessment shall include a review of the organization's systems using the Molding System Assessment. Successive Job Audits (Section 3.0 of this document) shall sample parts from different automotive component ‘manufacturers that require compliance to the Molding System Assessment document. ‘The assessment shall use the process approach to auditing/assessing as identified by the requirements of ISO/TS 16949,cal-23 Seat rete mens ho ars AIAG & Version 1, Issued 03/2014 Tha Catalyet or Peak Perfomance” Assessor Qualifications ‘Assessor(8) shall have the following specific experience to conduct the Molding System Assessment: 1, Bean experienced quality management system (QMS) internal auditor (for example, ISO/TS 16949, ISO 9001) 2. Assessor shall possess molding process knowledge. Evidence shall include a minimum. ‘of 5 years’ experience in molding processes or a combination of formal engineering, ‘education and molding 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 #1. Other Requirements ‘The organization shall keep records as evidence of compliance to the requirements identified in the Molding System Assessment, 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.AIAG.» gaze “The Catatst fr Pok Portrmance” Version 1, lsved 09/2014 1 SCOPE 1.1 General ‘This document specifies process requirements for an organization or its suppliers performing applicable molding, 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 Molding 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 Alll requirements of the Molding System Assessment are generic and are intended to be applicable to all organizations performing the molding operations addressed in this document, regardless of type, size, and product. Eight process tables have been developed and the appropriate table(s) is to be referenced during the assessment. The process tables are specific to molding processes as noted below: Process Table A — Injecting Molding ‘Receiving Inspection ‘© Storage and Handling © Material Drying * Recycle/Regrind Material * Color Management ‘+ Molding Process © Quality Control Process Table B ~ Blow Molding © Re ving Inspection © Storage and Handling © Material Drying + Recycle/Regrind Material * Color Management * Molding Process + Fluorine/Sulfination Treatment * Quality Controlcal-23 Sree ces: lng System Asean AIAG Version 1, Issued 0372014 Process Table C— Vacuum Forming Receiving Inspection Storage and Handling Forming Process Quality Control Process Table D ~ Compression Molding © Receiving Inspection © Compounding * Storage and Handling © Molding Process © Quality Control Process Table E - Transfer Molding (Thermoset Materials) © Receiving Inspection * Compounding and Preforming * Storage and Handling * Color Management * Molding Process © Quality Control Process Table F — Extrusion Receiving Inspection Storage and Handling Material Drying Recycle/Regrind Material Color Management Extrusion Process Quality Control Process Table G — Equipment— Process Control and Testing Equipment ‘© Process Equipment ‘© Secondary Equipment ‘+ Minimum Required Testing Capability PROCESS TABLE H - Part Inspection and TestingAIAG ‘The Cattyt for Pook Portrmarce cal-23 ‘Special Process: Molding System Assessment Version 4, Issued 03/2014 ‘These Process Tables (A through H) contain requirements for: 1 2, 3, 4, Process and Test Equipment Process Monitor Frequencies In-Process/Final Test Frequencies ‘Test Frequencies The Process Tables specify the tolerances of process parameters and the frequencies for checking process control parameters and parts.eai28 AIAG Specie Process: Molaing System Assessment a Version 1, sued 09/2014 The Catalyst for Peak Pororanes™ 2 THE MOLDING SYSTEM ASSESSMENT PROCEDURE 1. Obtain current copy of CQI-23 Special Process: Molding System Assessment from AIAG. 2. Identify all molding processes to which CQI-23 Special Process: Molding System Assessment applies (see CQI-23, 1.2). Record these processes on the Molding System Assessment cover sheet. 3. Complete the Molding System Assessment, including sections 1, 2 and all applicable process tables to determine the level of compliance. A minimum of one job audit (Section 3) 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. “Number of Process Table items identified as failed in Comments/Observation column” to be reported. 7, Assessments shall be conducted annually.AIAG 2 gona ‘Special Process: Molding System Assessment Version 1, Issued 03/2014 “The Gatlyet fr Penk Pater 3 SPECIAL PROCESS: MOLDING ASSESSMENT INSTRUCTIONS FOR COMPLETING THE COVER SHEET Coven Suter... INSTRUCTIONS FOR COMPLETING SECTIONS 1 ~2.. [MOLDING SYSTEMS ASSESSMENT... INSTRUCTIONS FOR COMPLETING THE JOB AUDIT.. 408 Auorr. smennnsnenennen dT ole“1d cal-23 Spas rots: Mong Sytum Assesment AIAG» Version 1, sued 03/2014 The Catalyst for Pook Fr INSTRUCTIONS FOR COMPLETING THE COVER SHEET 10, uM. Facility Name: Name of the facility being assessed. ty. The facility may have several buildings or physical the same general area, If there isa separate management team (Quality Manager and ) or different management system, then these locations shall be considered as separate facilities. Address: The street address of the facil additional information. ty being assessed; P.O. Box numbers may be given as Phone Number: The phone number ofthe facility. Ifthere is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used. Fax Number: The fax number of the facility. Number of Molding Employees at this Facility: The number of employees, salaried and hourly, associated with the molding operation at this facility. Captive Molder (Y/N): Enter “Y” ifthis facility molds components for their own company. Enter “N” if the company does not mold any components for their own company. ‘Commercial Molder (¥/N): Enter “Y” if this facility molds components for companies other ‘than their own company. Enter “N” if this facility does not mold any components for other companies. 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, 2016, Date of Previous Assessment: List the date of the previous Special Process: Molding System Assessment of this facility, Type(s) of Molding at this Facility: Place a checkmark to designate all molding 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 Molding System Assessment, Current Quality Certification(s): The molder 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, Date of Re-assessment (if necessary): If “Not Satisfactory” findings were observed from the original assessment, then the molder 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 — 3, 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. Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), if available, of the principal participants from the molder’s organization. Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), if available, of the auditor(s)AIAG os Special Process: Molding System Assessment ‘The Catalyst foc Pek Performs Version 1, lsued 0372014 15, 16. 17. Number of “Not Satisfactory” Findings: Enter the number of “Not Satisfactory” findings observed during the assessment, Number of “Needs Immediate Action” Findings: Enter the number of “Needs Immediate Action” findings observed during the assessment. Number of “Fail” Findings in the Job Audit(s): Enter the number of “Fail” findings observed from the job audit. Number of Process Table items identified as failed in Comments/Observation column: Enter the number of failed findings observed in the completed process tables. -13-CQI-23 Special Process: Molding System Assessment Version 1, Issued 03/2014 AIAG.» “The Catalyst ior Pook Purtorrance” Cover Sheet [Special Process: Molding System Assessment Foamy ae erat [Piss Roe frarrameer aa] of Wang Prosaanas a Precise Table (Rober of aang ERIS wa Fae fneeton lang [Comrise [Prsenan ToBI Procsae Tapa ea [roceee Tabs aT [carer Guany Careatoner a Re RSA TOS [Personnel Cora [ite era SE Fa [Rambo sacs nests Rao FaasAIAG 2a ganz “The Catv fr Penk Porlorsnco” ‘Version 1 Issued 03/2014 INSTRUCTIONS FOR COMPLETING SECTIONS 1-2 Sections 1 -2 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 ‘The assessor shall assess the molder’s compliance to Sections 1 — 2 by comparing the evidence presented by the molder to the requirements listed in the “Requirements and Guidance” column, NOTE I In the “Requirements and Guidance” column, the word “shall” indicates requirement and the term “such as” indicates that any suggestions given are for guidance only. NOTE2: 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 ‘molder’s compliance to the specified section(s) in the Process Tables. NOTE3: _ If the question is not applicable to the molder, then the assessor shall place a checkmark in the “N/A” Assessment cohumn. 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, NOTE4: 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 “seAIAG 2» (moynsong Anse, fesouep) woUssassy WarsKs BUIpIOW :ss200%4 er2adg Jersion 1, Issued 03204 ‘Special Process: Molding System Assessment 4 CQI-23 Molding SystemsCaQl-23 Special Process: Molding System Assessment Version 1, Issued 03/2014 AIAG» “The Catalyst fr Peak Patrmance™ auoo sons UREN SY ousossiour cep onsuen| eassoon auno pos pus ae ‘ecoeynes [ym souopia oanslao (mon1ong Aijoes [e10u99) uoWSSESsy WaASKs BUIPIOW :Sse90%4 feeds -I7-AIAG The Catalyst or Pek Peformance” usurp sus sg ous di 90 anos yo oy vonmopoese| ‘Stoord ust te slopeyoode Seon! una ou ee apo “pojroy asp wos 0 pause suosta|zpauEuew pve pauNDoE lmapesenneenesies Saucon. uens| “receshesieumanie| 0% See ay [uotmenes on] oesnes, [ym souapg san29400 Special Process: Molding System Assessment Version 1, Issued 03/2014 Cal-23 (marian Aytioe4 [e19u99) uWssessy Wa}skg BuIP|OW :ss900d [eIIeds -18-CQl-23 Special Process: Molding System Assessment 1, eeued 03/2014 Vers AIAG Te Catalyst fr Pek Perfomance” ‘eneaa pepe pe ese Sova ogedenseond Wee eau | = —— = a 7 TS (maqaieng Auiize Jes9U99) JuoUssessy We}SKs BuIploW :ss9D01g jeID0ds,AIAG» Tho Catalyst for Peak Peormorcs” Special Process: Molding System Assessment Version 1, Issued 0372014 CaQl-23 ‘ep onsen vosoase] oj pinot adr armraop poe Guo] ‘oj aersodon eave 0 280utH Fen aul| gee Un oO ‘Ssovanpayo waa o nopnal erate vo noua ‘emo = em eve | pue Sasser econ] V4 ‘ised uu e am opnou neve umes usboveu Aero ou sony susp nasa ourping ue uous onsen sun pa poy fHOEHENES ION} Accesses [ym 00 po pus uous, sone (malniong Ayize je1ousg) juowssassy worshs Buplow :ss92014 lel0ads -20-CaQl-23 Version 1, Issued 00/2014 ao pqsuedeas © uEweu Poe JOU =U Special Process: Molding System Assessment _, SIDEPE sone we Bue 2) Saver lors epposd foes ope owen Tausoned 209 ou oy sraseace age soranas pon enone (mayn1ong As1984 [240u99) uoUISsossy WHE}SAs BuIpIOW :8S300I4 JeI9ds AIAG» Tre Catalyst or Pak Priormanco™ aleAIAG» ho Catalyst or Pak Pertarmanee”™ Special Process: Molding System Assessment Version 1, lsued 0972014 CQl-23 -wondusp venpod squraw a sued ons fageyne eens pes pues sued a ‘hoas eon e uepteu pu danap ye ou | ‘havent pawounoop aey nes peu 94] ex} Kowersnes [vm souspyna mn2ei40 2p pus swowsunbon, vonseno, (malai0ng Aytioe4 (e10u99) 1uowssossy waISks BUIPION :ssa2014 [e}0dg 22CQi-23 Version 1, Isved 0372014 suse vse rea wossodep moss USER TPe| syd | tg sanpooois nwa vtznpox ogcuuenpoc| NECuhoean enon Saunporieuoumumcusmacrembore| "Ue Maumourad ez azn wae sunaue rs ue yumou oj wats oa oa 4 enoeoorte ogre mul] PIE of oe oe Special Process: Molding System Assessment uur Sua soornenes |x 2uep ean2eao -2>uepmno pur seuss vvoneen0) AIAG The Catalyst er Po Poermance™ (nopsoag Ase, fe10ue) juoWssessy Weyshs BuIploW :9800014 [e100ds ilAIAG» The Catalyst or ask arormence™ Special Process: Molding System Assessment Version 1, lsved 03/2014 CaQl-23 2 sainpscor panveunoop any us 2p a lrapeunty open souspag enol soueping pue susuianbon, — =a (maiasong Ayyioed 1e19u99) juaUissessy wle}Shs BuIPIOW :sse0044 [eloeds 24CQl-23 Special Process: Molding System Assessment Version 1, Issued 03/2014 AIAG» The Catalyst or Po Portornsnce” sar vod Sumi} ‘od oven oa fee unos | sce, ssomig iy sa seca uw pooads ce pawoped a vs somuarba ss son mon inpevoal esd urea ip esp paauncop 3 a ue pono Seuss ot 1 19 HE oo ae} no tone sued voszea pavoureop a | sammie onna ws ecunamsesey aren cen te] yay aes Sule emasen anneice Sema] _tsavoce erin spcuoo to wees appear teary] >To Sm pie jason fudonrsnoy seoanep Hee souspua ennzea0 counp pu suawennboy onsen (nataiong Ayioe4 jeiousp) usUssassy Warshs BuIpION) :ss9001g le!2eds-26- cae AIAG Special Process: Molding Systm Assessment a Version 1, Issued 00/2014 The Catalyst fr Pook Poforre INSTRUCTIONS FOR COMPLETING THE JOB AUDIT ‘The organization is to complete a minimum of one molding 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 ifthe 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 molding system assessment. ‘The job audit is not the only or main focus of the Molding System Assessment. The other two sections on ‘Management Responsibility and Quality Planning, and Floor and Material Handling Responsibility are equally if not even more important, The job audit of one part, one molding process, is not sufficient to use as a basis to complete the other sections of the complete Molding System Assessment. ‘The job audit is a compliance type audit/review of a specific part and its related paperwork and processing, including molding equipment and processing records for that job from the beginning receipt ofa part through processing in the molding operation and inspection to packaging. Parts shall be taken from the shipping area at the dock or the end of the molding operation. If an automotive manufacturer's partis not available or identifiable, then parts from other customers requiring compliance with this document shall be used for the assessment. The specific molding processing parameters (applies to 3.6 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 Mol System Assessment for the actual job/molding process being reviewed for compliance,caQl-23 Version 1, Issued 08/2014 Special Process: Molding System Assessment AIAG» The Catalyst for Peak Perfomance” Job Audit 27- se conta enpond mda oa | Teas os Suppou sun naudnong poveueW) ‘segura pens segs baal jo} 'ssequinu yed) voneoyquep! 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PROCESS TABLE 8: BLOW MOLDING PROCESS TABLE C: VACUUM FORMING .. PROCESS TABLE D: COMPRESSION MOLDING PROCESS TABLE E: TRANSFER MOLDING (THERMOSET MATERIALS). PROCESS TABLE F: EXTRUSION. PROCESS TABLE G: EQUIPMENT PROCESS TABLE H: PART INSPECTION AND TESTING 33AIAG» Tho Cotatst or Pak Poorrance Special Process: Molding System Assessment Version 1, Issued 0372014 CQI-23 Process Table A: Injection Molding 34CaQl-23 sued 09/2014 ‘Special Process: Molding System Assessment Version tsCQI-23 AIAG 2» The Catalyst for Peak Peformance” etsion 1 Issued 08/2014 ‘Special Process: Molding System Assessment Version 4,CaQl-23 Special Process: Molding System Assessment 4 Version 1, Issued 03/201 AIAG» “The Catalyst fr Pook Porforance™Special Process: Molding System Assessment Version, esved os720'4 CQI-23 AIAG.» # | i I | { i | Hi at San sonny 9 nanyas ng ey in ace ulCQl-23 ‘Special Process: Molding System Assessment " 014 Version 1, Issued 03/2 ‘The Catalyst for Pk Prtrance™ Process Table B: Blow Molding 39.Special Process: Molding System Assessment Version 1, Issued 0572014 Cal-23CQl-23 Special Process: Molding System Assessment Version 1, Issued 08/201 AIAG» “he Catalyst fr Pek Performance leSpecial Process: Molding System Assessment Vorson' sues oxzot8 Cal-23 42-CQl-23 Special Process: Molding System Assessment Version 1, Issued 0372014 AIAG jsvedpen aes ny el i i PUEEUE GG IIssued 037204 Special Process: Molding System Assessment Version 1, Issued 0372014 CQl-23 Process Table C: Vacuum FormingCaQl-23 Special Process: Molding System Assessment Version 7, lesuee 03/2034 AIAG» “The Catalyst fr Pook Parfranes™ eager arisen oe seme aoe sewer cy og ava omar tu sen oven rramnoanocrny| semen re maneomcey| “pongias be ey poe: Hedin ptod Yu ow we oungrbr uma “seuss nace or fone pn Un oH mone of eBay vou soma iam vans“ muna oR on fr | “sununnbas ypate macy 0 sapsogn a aoe an mua ‘Sujuuiog wnnaeq- J STEVI SSSOONSSpecial Process: Molding System Assessment “Issued 0872016 CQI-23 Version -46-CQl-23 Special Process: Molding System Assessment Version 4, Issued 03/2014 ‘Te Catayst fr Penk Peroomencs™ Process Table D: Compression Molding ‘Supjow uorsseudwop - GSTEVI SSIOONd -T-AIAG» “The Catalyst fer Pk Petormance™ Special Process: Molding System Assessment CQl-23 Version 1, sued 032014 48CQl-23 Version 1, Issued 03/2014 ore exo pu se] Special Process: Molding System Assessment swaunneas ne] on| sro| oen| semana nat (oe Ba ue AIAG» “Tha Catalyst fr Peak Performarcs™ ‘Suiplow uorsse:dwog- Ga TEV SSIOOUd -49-AIAG “The Catalyst fr Fone Poformarco™ Special Process: Molding System Assessment Version 1, lsved 03/2014 CQI-23 Process Table E: Transfer-Molding (Thermoset Materials)Cal-23 ‘Special Process: Molding System Assessment Version 1 Issued 09/2014 i u | i | i ps mon aon sa Aan eeu peg Boe Un = evento HEA Bune onda" esuyRbe! MONG hy A oneAIAG» “The Catlyt fr Peak Prormance™ Special Process: Molding System Assessment ve 4 ersion 1, Issued 03/201 CQI-23 sag hove avo] xy snow} besa _28) oye pcos bees me Se en nba saya ae alan Suipion s9ysue11 - 7FTEVI SHOUCQI-23 Special Process: Molding System Assessment Version 1, lsued 03/2014 “Tho Catalyst fr Peak Prtrmanoe™AIAG “he Catalyst fr Pak Perfomance” Special Process: Molding System Assessment 4 CaQl-23 ‘Version 1, Issued 037201 Process Table F: Extrusioncal-23 ‘Special Process: Molding System Assessment 4 Version 1, Issued 03/201‘Special Process: Molding System Assessment Version 1 issued 082014 cal-23 ‘uojsnuyg - 7 STEVI SSSOOWd 56CQl-23 ‘Special Process: Molding System Assessment ‘Varsion 4, ssued 032014 “The Catalyst or wowreasr ral eva swcncinome] HE | ros mnseptaxninin i ee ee paren ase maces) ht oe sd womwentn) HE | ons niin pa cree man] woop ammaunimereneol HE | ony sreunes ne vam ever] ores mmancen) HE ancy mee mre eee erasauneoaven| HE jaa oenare yaemo a werraeeg) | seme ney | memntoyumnam | vommcormy | wmumantny unum ad om, unt ncmon pmo et, serrata oon” | tu eeAIAG» “The Catalyet fr Peak Performance” pedo nn | Pinay i 2 i i i Special Process: Molding System Assessment 14 Version 1, Issued 03/201 CQI-23Cal-23 Special Process: Molding System Assessment 14 Version 1, Issued 03/20 Process Table G: Equipment = aaa ————— Tee | oeemneonans ——" rd tel SET) SES | ames | mers | Set | ta wer | pee | saumeans | Seat eoSpecial Process: Molding System Assessment Version 1, Issued 03/2014 CaQl-23 a —— = = co = = ed amar tenien| ee = ma = wo * ne = =CcQl-23 ‘Special Process: Molding System Assessment Version 1, tsued 08/2 Process Table H: Part Inspection and Testing AIAG» “Te Catayt fr Pook Petormarce” {| = 2 A ‘amu sa pow pos anal) ny tape oa oun Sopa ue po es oop eat eet tuna mb a ee 61-cal-23 ser castes Den essa AIAG Version 1, lsued 0372014 The Coalst for Pook Petrmare GLOSSARY Additive: A substance compounded into a resin to enhance or improve certain characteristics, Assembly: The process of joining parts by any of several methods. ASTM: American Society for Testing and Materials. Back Pressure: The resistance of the molten plastic material to forward flow. In molding, back pressure increases the temperature of the melt, and contributes to better mixing of colors and homogeneity of the material. However, as back pressure increases, so does cycle time. Barrel: The section of a molding machine that contains the feed screw, also the section where resin heating and mixing occurs, Blister: An imperfection on the surface of a plastic article caused by a pocket of air or gas beneath the surface, Blow Molding: Method of fabrication in which a warm plastic hollow tube is placed between the two halves of a mold cavity and forced to assume the shape of that mold cavity by use of internal pressure, Cavity: A depression, or a set of matching depressions, surfaces of the molded articles. a plastics-forming mold which forms the outer Charge: The measurement or weight of material necessary to fill a mold during one cycle. Clamping Pressure: The pressure applied to the mold to keep it closed during the molding cycle. Closed-loop Control: System for monitoring and automatically adjusting injection molding process conditions such as temperature, pressure and time, The automatic changes keep part production within preset tolerances. Compound: A mixture of resin(s) and additives usually formed in a separate machine downstream from the primary reactor. Compounding: The process required to mix polymer(s) with all ofthe additives that are necessary to provide the end user with a finished grade with suitable properties. ‘Compression Molding: A method of molding in which the molding material, generally preheated, is placed in an open heated mold cavity, the mold is closed with a top force, pressure is applied to force the material into contact with all mold areas. Cooling time: The elapsed time required for the melt to reach its Vicat softening temperature. Crack/Splits/Chips: A physical separation or tearing of the part CSA: Canadian Standards Association, Cycle Time: The position/state. 1e required by an injection molding system to mold a part and return to its original Cycle: Complete, repeating sequence of operations for injection molding a part.AIAG cosas strona ein oS ‘The Catlyet for Pek Pertarmance’ Version 1, Issued 08/2014 Density: Mass per unit volume of a substance. Drying: The removal of moisture from the resin pellets by exposure to certain time and temperature. All Hydroscopic Material must be dried prior to molding, Extrusion: The process of forming continuous shapes by forcing a molten plastic material through a die. Fiber: This term usually refers to thin fibers of glass which are used to reinforce materials. One-inch long fibers are occasionally used, but the more commonly used fiver lengths are 1/2” and 1/4", or ess. Fill Time (also known as Injection): Time required to fil he cavity or mold. Fill: The packing of the cavity or cavities of the mold as required to give a complete part or parts that are free of flash and porosity. Finish: The surface texture and appearance of a finished article. Flash: Any excess material that is formed with and attached to the component along a seam or mold parting line. Flow Rate: The volume of material passing a fixed point per unit time. Gate: The channel through which the motten resin flows into the cavity Injection Molding: The method of forming objects from granular or powdered plastics, most often of the thermoplastic type, in which the materials is fed from a hopper to a heated chamber in which itis softened, after which a ram or screw forces the material into a mold. Pressure is maintained until the ‘mass has hardened sufficiently for removal from the mold, Insert Molding: The process of molding plastic around another object that has been placed into the mold cavity before the injection of molten resin. Knit Lines: Where melted material flows together to form a line or lines that may cause weakening or breaking of the component. Lubricant: Internal lubricants, without affecting the fusion properties of a compound, promote resin flow, External lubricants promote release from metals which aids in the smooth flow of melt over die surfaces. Melt Flow: Rate of extrusion of molten resin through a die of specified length and diameter. The conditions of the test (e.g. temperature and load) should be given. ‘Mold (n): A hollow form or matrix into which a plastic material is placed and whic! its final shape as a finished article. parts to the material ‘Mold (v): To impart shape to a plastic mass by means of a confining cavity or matrix. Mold Release: In injection molding, a lubricant used to coat the surface of the mold to enhance ejection of the molded article or prevent it from sticking to the tool Mold Temperature: The temperature at which the mold is maintained. Often the most important benefit of raising mold temperature is that it allows a slower injection rate without the plastic getting too cold. Mold-Temperature-Control Unit: Auxiliary equipment used to control mold temperature. Some units can both heat and cool the mold. Others, called chillers, only cool the mold. 63--64- = AIAG 2 Version 1 lssued 03/2014 “The Catalyst for Pek Partormance™ Nozzle: Hollow metal hose screwed into the extrusion end of the heating cylinder of an injection machine designed to form a seal under pressure between the cylinder and the mold, Pellets: Tablets or granules of uniform size, consisting of resins or mixtures of resins with compounding ‘additives which have been prepared for molding operations by extrusion and chopping into short segments. Pigment (also known as Colorant, Color Concentrate): A plastic compound which contains a high percentage of pigment, to be blended in appropriate amounts with the base resin so that the correct final color is achieved. Preform: A plastic pre- shaped part produced by injection molding systems in the first step of a two-stage injection molding and blow molding process used to produce bottles or containers. The preform is. subsequently re-heated and stretch blown through a biow molding process into the fina container shape. Purging: In extrusion or injection molding, the cleaning of one color or type of material from the machine by forcing it out with the new color or material to be used in subsequent production, or with another compatible purging material. Recovery Time: The length of time for the screw to rotate, create a shot, and retum to original position. Regrind: Waste material such as sprues, runners, excess parison material and reject parts from injection molding, blow molding and extrusion, which has been reclaimed by shredding or granulating. Regrind is usually mixed with virgin compound at a predetermined percentage for remolding, Resin (Synthetic): The term is use to designate any polymer that is a basic materi for plastics. Robot: Automated devices for removing parts upon ejection from an open mold rather than letting the parts drop. Also see parts picker. Robots also can perform secondary functions, such as inspection, degating, precise placement of parts on a conveyor, etc. ‘Trap Points: Areas in containers (baskets, fixtures, shipping boxes, etc.) or any equipment that may inadvertently retain parts, allowing the potential for parts to be mixed between batches. Short Shot (also known as Non-Fill: Failure to completely fl the mold or cavities of the mold. Edges may appear melted. ‘Shrinkage: Contraction upon cooling of all or areas of the part. Shrinkage occurs less in disorientated material and more across chains of molecules than along their lengths. Lower pack areas have lower areas of orientation and shrinkage. ‘Sink Mark: Depressions in the surface of a molded part caused by local internal shrinkage after the gate seals. Sink is most common in thick sections of a part or where features such as ribs or bosses intersect avisual surface. ‘SMC (Sheet Molding Compound): A ready to use glass fiber reinforced polyester material primarily Used in compression molding. Specific Gravity: The ratio of the density of a material as compared to the density of water at standard ‘atmospheric pressure (1 ATM) and room temperature (73F), ‘Splay Marks: Scan or surface defects on molded part caused by abnormal racing of the mett in the moldAIAG» spel Process: dng Systm Sent The Catalyst or Pak Prermance™ Version 7, Issued 0372014 Tensile Strength: The maximum tensile stress sustained by the specimen during a tension test. ‘Thermoset: A polymer that imeversibly cures. Once hardened a thermoset resin cannot be reheated and, melted to be shaped differently ‘Thermo Plastic: A polymer that becomes pliable and moldable above a specific temperature, and returns toa solid state upon cooling. ‘Transfer Molding: A process of forming articles by fusing a plastic material in a chamber then forcing the whole mass into a hot mold to solidity Vacuum Forming: A process whereby a heated plastic sheet is drawn against a mold surface by evacuating the air between it and the mold Vestige: A visible mark created by the gate. iscosity: Resistance to flow of a liquid. Void: An unfilled space within a solid material Weld Line: Where melted material flows together during molding to form a visible line or lines on a finished part that may cause weakening or breaking of the component. 65°-66- ae AIAG 2 Version 1, lesued 03/2014 “The Cotter Pek Porton” [MAINTENANCE REQUEST FORM Name of Submitter: Date: Company: Company Address: Phone: Fax: E.me RNa sou Page Number of Change: Document Currently Reads: Recommended Changes/Should Read: Reason for Change (Use additional she Signature of Submitter: PISS aa) Manager's Recommendation: Final Disposition: Comments: Telephone: (248) 358-3570 + Fax: (248) 358-3253, eMail: quality@aiag.org Web: www.aiag.org