Checking date　　　　　　　/　　　　/　　　

Quenching and tempering process check sheet

[Audit destination 1]
Approved Examined Witnessed
Part by by by
Model
number

Audit
destination

[Audit destination 2]
Approved by Examined Approved Examined Witnessed
Audited by by by by by

Audit result

Achievement degree per field

Field
Trial
1st prototype productio Production Full score A
n

Quality control I 1.000 B

A system 12 15 30 34
Safety/
B Environment 2 8 10 12 0.500

C Production setup 3 7 10 23 H C
0.000
D Material control 4 6 8 11
Material
E processing 20 30 30 43
G D
F Heat treatment 10 20 30 44
Inspection after
G heat treatment 7 9 12 37 F E
Processing after
H heat treatment 1 1 2 2
1st prototype Trial production Production
I Secondary supplier 2 3 3 4
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　　Quenching and tempering process check sheet　　1/3

◎：MUST, ○：WANT

Audit Result (OK / NG)

Checking item Process in detail Criticality Checking item Objective Evident
Trial Mass Abnormal
1st prototype
production Production Situation

Quality control system Qualtiy Control ◎ Is the standard or the like posted on the line? WI availble in all stages

Quality control system Qualtiy Control ◎ Is there a plan available for operator training? Yes. Training plan Available

Quality control system Qualtiy Control ○ Is there qualification system available for operator? Yes Competency matrix Available

Quality control system Qualtiy Control ○ Is there a list of qualified operator available? Yes Skill matrix Available

Quality control system Qualtiy Control ◎ Is an action specified when short time machine-down occurs (safety and production)? Yes. Contigency Plan Available

Quality control system Qualtiy Control ○ Is it ensured that the initial product, periodic product, and final product or every lot can be checked? No. Final Product only checked

Quality control system Qualtiy Control ◎ Is there a trouble measure rule available? If it is, is there a record of remedy available? Yes. Contigency Plan Available

Yes. NC part handling procedure

Quality control system Qualtiy Control ◎ Is there a nonconforming product disposal rule available? If it is, is there a record of remedy available?
available SCP/QSP/14

Quality control system Qualtiy Control ◎ Are trouble item, person in charge and action schedule specified? yes.

Quality control system Qualtiy Control ○ Is the detail of past quality failure of similar parts comprehended? Not Applicable

Quality control system Qualtiy Control ○ Is a measure against past quality failure of similar parts incorporated? Not Applicable

Quality control system Qualtiy Control ◎ Are 5S done well enough? Yes Satisfactory

Yes. QCPC available

Quality control system Qualtiy Control ◎ Is there QC process chart available?
SCP/KYB/QCPC/CAP/64096
Are the condition, standard, measurement item, frequency, and person in charge indicated in QC
Quality control system Qualtiy Control ◎ process chart?

Quality control system Qualtiy Control ◎ Is the inspection standard approved (10 days before delivery of trial product)? Inspection standard Available

Quality control system Qualtiy Control ◎ Is a drawing consistent with shop drawing, work standard, and inspection standard? Work Standard Available

Quality control system Qualtiy Control ◎ Is a system established for initial control? Yes.

Quality control system Qualtiy Control ○ Is a capability examined incorporating failure rate? yes. 9 point measurement available

Quality control system Pokayoke ○ Is there Pokayoke available? If there is, is the operation checked? No Pokeyoke

Quality control system Pokayoke ◎ Is it ensured that wrong part cannot be set? No Pokeyoke

BPQ
Quality control system
(5 basic principles) ◎ Is Yarikiri work (BPQ-001) observed? Not Appilcable

BPQ
Quality control system
(5 basic principles) ◎ Is "Observance of work standard (BPQ-002)" observed? Not Appilcable

BPQ
Quality control system
(5 basic principles) ◎ Is "Treatment for Shirohata parts (BPQ-007)" observed? Not Appilcable

BPQ
Quality control system
(5 basic principles) ◎ Is "Identification of parts before and after processing (BPQ-008)" observed? Not Appilcable

BPQ
Quality control system
(5 basic principles) ◎ Is "Treatment judgment for non-conforming parts (BPQ-012)" observed? Not Appilcable

Quality control system Processing quality ◎ Is heat treatment condition clearly specified by heat pattern, etc? Work Instruction avaiable

Quality control system Processing quality ◎ Is it ensured that the standard can be satisfied by that condition? Yes. Satisfied

Quality control system Processing quality ◎ Is heat treatment condition made visible on equipment side including allowable range? Yes.

Quality control system Processing quality ◎ Is it ensured that every part can be set without interfering with jig, etc? Yes

Quality control system Processing quality ◎ Does a product satisfy all inspection method requirements? Hardness, only

Is it possible that a part is damaged in a process (such as scratch and nick)? If it is, is there a
Quality control system Processing quality ◎ countermeasure?
No Applicable

Quality control system Processing quality ◎ Is it ensured that a product can be taken out easily from the heat treatment basket and equipment? Yes. User friendly

Change Management Procedure

Quality control system Process change ◎ Is the process change rule understood? (Is there a provision available pursuant to Yamaha rule?)
available

Quality control system Process change ◎ Is a change operated according to the rule? Is there a record available? No Changes

Safety/ Environment Safety ◎ Is safety of production work ensured? Yes,. Satisfied

Safety/ Environment Safety ◎ Is safety of transporter and collector ensured (including the handling of heavy weights)? yes.

Safety/ Environment Safety ◎ Is periodic maintenance manual prepared for the equipment? Used Fork lift Trolleys

Dilay, Weekly and Yearly plan

Safety/ Environment Safety ○ Is there daily, weekly, monthly, and yearly inspection plan made available?
Available

Safety/ Environment Safety ○ Is a spare for jig available? Yes. Available

Safety/ Environment Safety ◎ Is the equipment operation procedure manual prepared? Work instruction Available

Is the equipment resetting (emergency stop, origin return, and short time machine-down) training Yes. Emegency stop button available.
Safety/ Environment Safety ○ performed? Performed 3 months once

Safety/ Environment Safety ◎ Is program data backed up such as heat treatment condition? Yes Backup data available

Safety/ Environment Safety ◎ Is there a storage rule of program data available such as heat treatment condition? Yes available

Safety/ Environment Safety ○ Is the risk management sufficient in emergency? (Are rule such as procedure manuals provided?)

Safety/ Environment Safety ○ Is danger degree comprehended? (Is risk management performed?)

Safety/ Environment Safety Is a measure plan made assuming emergency situation?

Safety/ Environment Safety Is the above verified by trial?

Safety/ Environment Safety Is the result of safety inspection accepted?

Atmosphere/ Water
Safety/ Environment
pollution ○ Authorized by ISO14001? Yes ISO 14001: 2015 Certified

Production setup Production Setup ○ Is actual goods slip issued? Ys. Production Register available

Production setup Production Setup ○ Is a heat treatment basket made ready sufficiently (design and quantity)? Yes.

Production setup Production Setup ◎ Is the stock area separated clearly before and after heat treatment for every part? yes.

Production setup Production Setup Is the target of failure rate attained? yes.

Production setup Production Setup ○ Is the cause of in-process failure analyzed and countermeasure taken sufficiently? Yes. PFMEA available

Yes. QCPC available

Production setup Line setup ◎ Is there QC process chart available?
SCP/KYB/QCPC/CAP/64096

Production setup Line setup ◎ Does the guarantee conform to QC process chart? Yes. Process carried as per QCPC

Production setup Line setup ○ Is there a system available on the line for finding and eliminating a trouble?

Production setup Line setup ○ Is there a correction rule specified on the line?

Yes. NC part handling procedure

Production setup Line setup ◎ Are there rejected part disposal rule and procedure manual available?
available SCP/QSP/14

Production setup Line setup ◎ Is the daily check sheet of equipment completed?

Production setup Line setup ◎ Are 5S alright? 5S saitified

Yes. NC part handling procedure

Production setup Line setup ○ Is there a rejected part shelf? Rejected parts are processed according to rejected part disposal rule?
available SCP/QSP/14

Production setup Line setup ◎ Is there a work standard in each process? Yes. WI Available for all stages

Production setup Line setup ◎ Are part number, etc indicated in the stock area of supplied parts? Yes. Register available

Production setup Line setup ◎ Is there stock area for completed products? Not Applicable

Production setup Line setup ○ Is delivery packaging style specified? Not Applicable
 3／8
Production setup Line setup ○ Is delivery container made available? yes. Available

Production setup Line setup ◎ Is the destination of parts made clear? Not Applicable

Production setup Line setup ◎ Is there work instruction manual (procedure manual) available? Yes. WI Available for all stages

Production setup Line setup ○ Is it ensured that an operator can easily observe a specified standard operation? Yes. WI Available for all stages

Is it ensured that an operator can find any trouble of parts within standard operation (such as un-
Production setup Line setup ○ processing and mixing)?
Yes. Std. Available

Production setup Line setup ○ Is there a procedure available for transport and move? Not Applicable

Production setup Line setup ○ Are there a procedure and system available for correction? Yes. Available

Production setup Cycle time Is there a target of cycle time available? Yes. Available In WI

Production setup Cycle time Is the target of cycle time satisfied? Yes.

Material manufacturer
Material control Is a purchasing route specified including trading company or coil center name? Yes. Jindal Aluminium
name

Material control Material specification Is the quality specification arranged with material supplier? Yes. 6061 T4

Material control Material specification Is the material specification stored? Parts stores in

Material control Material specification ○ Is material used with its component controlled within narrow range for stabilizing the hardenability?

Material control Standard Is it made clear which standard the material is pursuant to in manufacturing (GB, JIS, …)? Yes. A6061

Steel manufacturing
Material control Is vacuum degassing process performed? If it is, is it indicated on the specification? No Applicable
method
Steel manufacturing
Material control Is forge ratio of slab above 6S? No Applicable
method
Steel manufacturing Is the range of drawing rate of drawing material specified? (Is the outside diameter before drawing
Material control No Applicable
method specified?)
Steel manufacturing
Material control Is the range of spheroidizing rate specified for spheroidizing annealing material? No Applicable
method

Material control Alloy component Is it checked before acceptance that Cr, Mo, and Ni are within the range of specification? No Applicable

Material control Material component Is the material controlled by type? No Applicable

Material control Crystal grain size Is there the standard of crystal grain size available? (JIS 6 - 8 is appropriate.) No Applicable

Material control Crystal grain size Are the size and allowable quantity of inclusion specified? No Applicable

Material control Crystal grain size Is there the standard of oxidizing and decarburizing available? No Applicable

Material control Crystal grain size Is there the standard of surface scratch available (below 0.2mm for cold forging application)? No Applicable

Material control Hardenability Is there the standard of hardenability available? No Applicable

Material control Charge control ◎ Is there a system for tracking material lot? Yes. Through Heat no.

Material control Charge control ◎ Does the process change rule include the change of material manufacturer?

Material control Material control ◎ Is the material controlled by its type?

Material control Material control ◎ Is the storage area of material specified?

Material control Material control ◎ Are any measures taken to prevent the mixture of foreign substance?

Material control Material control ◎ Is the control method specified for mill ends and excess material?

Material control Material control ◎ Is the control method specified such as storage method?

Material control Material control ◎ Is the material used specified on the drawing? Yes. A 6061

Material control Material control ◎ Is the lot controlled and FIFO observed? Yes. Through Heat no.

Material heat treatment

N, A, SA, and H
Equipment control ○ Is there the maintenance record of equipment available?

Material heat treatment

N, A, SA, and H
Loading packaging style ◎ Is the upper/lower limit controlled for furnace charging quantity?

Material heat treatment

N, A, SA, and H
Loading packaging style ○ Is there a rule for mixed loading with any other part?

Material heat treatment

N, A, SA, and H
Loading packaging style ○ Is the heat treatment basket (anti-cementation pallet) controlled sufficiently? (design/quantity)

Material heat treatment

N, A, SA, and H
Treatment time ◎ Is heat treatment time specified clearly on the instruction sheet?

Material heat treatment

Treatment time Is heat treatment time within a general condition range for corresponding material and product size?
N, A, SA, and H
Material heat treatment
N, A, SA, and H
Treatment time ◎ Is treatment time recorded?

Material heat treatment

N, A, SA, and H
Treatment temperature ◎ Is heat treatment temperature specified clearly on the instruction sheet?

Material heat treatment Is heat treatment temperature within a general condition range for corresponding material and product
Treatment temperature
N, A, SA, and H size?
Material heat treatment Is the furnace temperature recorded? (It is preferable that the temperature is recorded on a chart
N, A, SA, and H
Treatment temperature ◎ continuously.)
Material heat treatment
N, A, SA, and H
Treatment temperature ◎ Is the thermometer calibrated periodically for measuring the furnace temperature?

Material heat treatment

N, A, SA, and H
Treatment temperature ◎ Is the measurement result of furnace temperature stored and controlled?

Material heat treatment Is the temperature variation evaluated resulting from position in the furnace? (Is there track record of
N, A, SA, and H
Treatment temperature ◎ measuring nine points in the furnace?)
Material heat treatment
N, A, SA, and H
Atmosphere control ◎ Is appropriate control applied conforming to carbon content of material?

Material heat treatment

N, A, SA, and H
Heating system ○ Is the temperature on work outside controlled in consideration of radiant heat (when control is on or off)?

Material heat treatment Is cooling method specified on the instruction sheet such as water cooling or oil cooling, availability of
N, A, SA, and H
Cooling method ◎ agitation, etc?
Material heat treatment
N, A, SA, and H
Coolant temperature ◎ Is the temperature of coolant recorded?

Material heat treatment

N, A, SA, and H
Coolant temperature ◎ Is the range of coolant temperature specified?

Material heat treatment

N, A, SA, and H
Coolant performance ◎ Is the performance of coolant measured and controlled periodically (every 3 months)?

Material heat treatment

N, A, SA, and H
Hardness ○ Is it inspected that hardness irregularity is not found?

Material heat treatment

Crystal grain size Is the crystal grain size measured (record of result available)?
N, A, SA, and H
Material heat treatment
N, A, SA, and H
Jig control ○ Is there a disposal criterion for a jig with severe oxidization or damage?

Processing (forging) Forging ○ Where can it be found when foreign material mixes in?

Processing (forging) Forging ◎ When foreign material mixes in, can the history be tracked?

Processing (forging) Forging Is a defect such as contamination forecasted by forging analysis?

Processing (forging) Forging ○ Is acceptability judgment criterion specified for initial product checking?

Processing (forging) Forging ◎ Are wrinkle and lap inspected after cleaning by magnetic- pawder examination?

Processing (forging) Forging ◎ Are the measurement point and frequency of intermediate product specified by standard, etc?

Is it ensured that handling after pressing and intermediate packaging style do not cause nick and
Processing (forging) Forging ○ deformation?

Processing (forging) Forming degree Does the forming degree take into consideration the heat treatment distortion?

Processing (forging) Lubricating process ○ Is a portion that requires hardness free from bonderizing process and forging skin?

Processing (forging) Fiber flow Is there inspection system of fiber flow?

Processing (forging) Fiber flow Is the inspection control method of fiber flow specified by standard, etc?

Processing (forging) Fiber flow Is there any inspection record of fiber flow available?

Processing (forging) Workmanship check ○ Is hardness inspected after processing?

Processing (forging) Workmanship check Is the organization inspected after processing?

 4／8
Processing (forging) Workmanship check Is it ensured that process that leaves residual distortion is not applied such as strain relief?

Processing (forging) Workmanship check Is decarburization inspected?

Processing (forging) Workmanship check ○ Are the wrinkle, scratch, and crack inspected?

Processing before heat

treatment
Toll and jig ◎ Are the tool and jig controlled?

Processing before heat

treatment
Processing condition ○ Is a processing condition set that does not lead to deep cuts?

Processing before heat

treatment
Machining allowance ○ Is a machining allowance set large enough to remove material decarburization?

Processing before heat Is the precision before heat treatment measured and controlled for distinguishing from that after heat
Processing precision
treatment treatment (distortion)?

Cleaning after processing Cleaning packaging style ○ Free from cleaning irregularity?

Cleaning after processing Cleaning method ◎ Are appropriate detergent and method applied to removing of cutting oil?

Cleaning after processing Cleaning time ◎ Is time set and controlled enough for satisfying product quality?

Cleaning after processing Cleaning temperature ◎ Is the criterion of temperature range set and controlled?

Cleaning after processing Cleaning liquid control ◎ Is a control criterion set such as replacement frequency of detergent?

Cleaning before heat

treatment
Cleaning packaging style ○ Free from cleaning irregularity?

Cleaning before heat

treatment
Cleaning method ◎ Is alkaline immersion, shower, or solvent cleaning available? (Alkaline immersion is the best.)

Cleaning before heat

treatment
Cleaning time ◎ Is time set and controlled enough for satisfying product quality?

Cleaning before heat

treatment
Cleaning temperature ◎ Is the criterion of temperature range set and controlled?

Cleaning before heat

treatment
Cleaning liquid control ◎ Is control criterion set such as replacement frequency of detergent?

Heat treatment Equipment control ◎ Is there a work standard available? (Are the temperature, heat treatment time, and hardness specified?)

Heat treatment Equipment control ◎ Is the timing specified and operated for evaluating temperature variation due to position in the furnace?

Heat treatment Equipment control ◎ Is the timing specified and operated for evaluating hardness variation due to position in the furnace?

Heat treatment Equipment control ◎ Is a rule specified and operated for checking and calibrating the precision of hardness gage?

Heat treatment Equipment control ◎ Is hardness measurement included in inspection item?

Heat treatment Equipment control ◎ Is a rule specified for remedy when hardness is NG?

Heat treatment Equipment control ◎ Is the layout of products specified?

Heat treatment Equipment control ◎ Is the equipment checked daily?

Heat treatment Gas organization ○ Is raw material gas and conversion condition controlled?

Atmosphere control
Heat treatment
system ◎ Does the sensor function properly (measurement for controlling Cp value)? Not Applicable

Atmosphere control
Heat treatment
system ◎ Is a rule specified for calibrating the sensor? Not Applicable

Atmosphere control
Heat treatment
system ◎ Is double check applied by measurement of TP hardness, etc? Not Applicable

Atmosphere
Heat treatment
concentration ○ Is the work surface area controlled for stabilizing the atmospheric density? Not Applicable

Atmosphere
Heat treatment
concentration ○ Is there a rule available for adjusting the atmospheric density by work charging amount (surface area?) Not Applicable

Atmosphere
Heat treatment
concentration ◎ Is the measurement by Cp sensor properly fed back to the atmospheric control? Not Applicable

Atmosphere
Heat treatment
concentration ○ Are the control result and value of atmosphere recorded? Not Applicable

Heat treatment Treatment time ○ Is the treatment time controlled properly by the configuration and surface area of work? yes. Controlled

Heat treatment Treatment time ○ Is the control result of treatment time recorded? yes. Through Panel board

Heat treatment Treatment temperature ○ Is an appropriate treatment temperature set for requirement? yes. WI Available

Heat treatment Treatment temperature Is there inspection data available proving that requirement is satisfied? yes. Satisfied

Heat treatment Treatment temperature ◎ Is a treatment temperature measured? yes. Through Panel board

Heat treatment Treatment temperature ◎ Is the setting position of thermocouple specified?

Heat treatment Packaging style ◎ Is the quantity of charging controlled?

Heat treatment Packaging style ◎ Is a criterion set for loading mixed with other parts?

Is the temperature controlled on the outer surface of work in consideration of radiant heat (when control
Heat treatment Heating system ○ is on-off system)?

Heat treatment Quenching

Heat treatment Quenching temperature ◎ Is the quenching temperature measured?

Heat treatment Quenching temperature ◎ Is the criterion of temperature set and controlled?

Quenching oil
Heat treatment
temperature ◎ Is the temperature of quenching oil measured?

Quenching oil
Heat treatment
temperature ◎ Is the criterion of quenching oil temperature set and controlled?

Heat treatment Quenching time ◎ Is the retention time in quenching oil set and controlled?

Heat treatment Quenching oil ○ Are the type and brand of quenching oil specified?

Heat treatment Quenching oil ◎ Is quenching oil used at the temperature recommended by its type and brand?

Heat treatment Quenching oil ○ Can the deterioration of quenching oil be measured?

Heat treatment Quenching oil ◎ Are the criterion and frequency set for changing or refilling quenching oil?

Quenching packaging
Heat treatment
style ○ Is cooling oil set to ensure layered flow, and is thin material placed vertically?

Heat treatment Oil agitation condition ◎ Is the agitation condition of quenching oil set?

Heat treatment Tempering

Heat treatment Tempering temperature ◎ Is the tempering temperature set conforming to the function?

Heat treatment Tempering temperature ○ Is time controlled from quenching to tempering?

Heat treatment Tempering temperature ◎ Is it ensured that tempering is not at a temperature within tempering fragility area (250 - 450C)?

Heat treatment Tempering temperature ◎ Is the tempering temperature measured?

Heat treatment Tempering temperature ◎ Is the tempering temperature measurement device calibrated?

Heat treatment Tempering temperature ◎ Is the tempering temperature measurement result recorded?

Heat treatment Tempering temperature Is it checked that no variation is found for tempering hardness?

Heat treatment Treatment time ◎ Is the tempering time measured?

Heat treatment Treatment time ◎ Is the measurement result of tempering time recorded?

Is the temperature controlled on the outer surface of work in consideration of radiant heat (when control
Heat treatment Heating system
is on-off system)?

Heat treatment Packaging style ◎ Is the upper and lower limit set for charging quantity?

Inspection after Heat

treatment
Inspection system ○ Is there a special inspection system (N1000-N1) available when starting mass production? Process Validation report available

Inspection after Heat Are the shipment inspection method and judgment criterion made clear (function, appearance, and
treatment
Inspection system ◎ measurement)?
Yes. Available

Inspection after Heat

treatment
Inspection system ◎ Is process capability taken into consideration for sampling quantity of in-process inspection? Not Applicable

Inspection after Heat Is acceptance inspection carried out for supplier's parts? (Are the items and inspection quantity
treatment
Inspection system ◎ reasonable?)
Not Applicable
 5／8
Inspection after Heat
treatment
Inspection system ○ Is there a control criterion available for new process and new function parts (net of assurance)? Not Applicable

Inspection after Heat

treatment
Inspection system ◎ Is the history of engineering change made clear? (System) Not Applicable

Inspection after Heat

treatment
Inspection system ◎ Is the latest engineering change incorporated to the parts? NO ECN

Inspection after Heat

treatment
Inspection system ○ Is the detail of quality failure comprehended of similar parts in the past?

Inspection after Heat

treatment
Inspection system ○ Is the measure against quality failure incorporated of similar parts in the past?

Inspection after Heat

treatment
Inspection system ◎ Are trouble item and person in charge of action schedule specified?

Inspection after Heat

treatment
Inspection system ◎ Is the system of initial control established?

Inspection after Heat

Inspection system Is there a qualified metallic heat treatment engineering technician? yes. Avaialble
treatment
Inspection after Heat
treatment
Flaw detection ◎ Is there equipment available for nondestructive flaw detection? Not Applicable

Inspection after Heat

treatment
Flaw detection ◎ Is there a nondestructive flaw detection work standard available? Not Applicable

Inspection after Heat

treatment
Flaw detection ◎ Are the inspection frequency and position indicated on the work standard? Not Applicable

Inspection after Heat Is a nondestructive inspection operator trained by a qualified person? Is there a training record
treatment
Flaw detection ◎ available?
Not Applicable

Inspection after Heat

treatment
Flaw detection ○ Is it ensured that fabric gloves such as cotton gloves are not used (visual mistake in inspection)? Not Applicable

Inspection after Heat

treatment
Flaw detection ○ Does nondestructive flaw detection cover 100%? (If not, what kind of criterion is applied to sampling?) Not Applicable

Inspection after Heat

treatment
Flaw detection ◎ Is the inspection record of nondestructive flaw detection kept (prototype and trial production)? Not Applicable

Inspection after Heat

treatment
Flaw detection ◎ Is a flaw detected over all the surface of work? Not Applicable

Inspection after Heat

treatment
Flaw detection ◎ Are any corrective measure and correction route specified when flaw detection result is NG? Not Applicable

Inspection after Heat

treatment
Flaw detection ◎ Is there a defective part disposal rule available? Is it appropriate? Not Applicable

Inspection after Heat Measurement device

treatment control ◎ Does the inspection equipment match with inspection method (Quality standard) requirement item? Yes. Hardness tester

Inspection after Heat Measurement device

treatment control ◎ Can the jig and gage set to the parts easily? Yes.

Inspection after Heat Measurement device

treatment control ◎ Is it ensured that no unmeasurable item of parts is found? not Applicable

Inspection after Heat Measurement device

treatment control ○ Is the replacement frequency specified for hardness reference piece? No

Inspection after Heat Measurement device

treatment control ○ Is daily check carried out on hardness reference piece? Yes. Available

Inspection after Heat Measurement device

treatment control ○ Is a daily check record of hardness measurement equipment left on check sheet, etc? Yes. Register Available

Inspection after Heat Micro stracture

treatment inspection ○ Can a specimen be adjusted appropriately for observing structure? No Applicable

Inspection after Heat Micro stracture

treatment inspection ○ Is there a system available for storing actual inspected product? No.

Inspection after Heat Micro stracture

treatment inspection ◎ Is there an evaluation criterion of micro structure available on the line? not Applicable

Inspection after Heat Micro stracture

treatment inspection ○ Is there any organization recording device available? not Applicable

Inspection after Heat Micro stracture

treatment inspection ◎ Is there any corrective action specified when organization NG occurs? not Applicable

Inspection after Heat

treatment
Hardness inspection ◎ Is the acceptability judgment criterion of surface hardness made clear? Yes. Standard available

Inspection after Heat

treatment
Hardness inspection ◎ Is the result of hardness measurement stored? Yes. Register Available

Inspection after Heat

treatment
Hardness inspection ◎ Is a measurement position specified (both surface and section)? Yes. Specified

Inspection after Heat

treatment
Hardness inspection ◎ Is a measurement position observed? Yes. Observed

Inspection after Heat

treatment
Hardness inspection ◎ Is there any corrective action specified when hardness NG product is found? Yes. Reaction plan available

Processing after heat

Bend correction Is distortion correction incorporated to formal process? Not Applicable
treatment
Processing after heat
Bend correction Is a die prepared for correcting distortion? Not Applicable
treatment
Processing after heat
Bend correction Is the upper load limit set for distortion correction? Not Applicable
treatment
Processing after heat
Bend correction Is a crack inspected for after distortion correction? Not Applicable
treatment
Processing after heat
treatment
Shot peening ○ Are the condition, standard, measurement item, frequency, and person in charge indicated? Not Applicable

Processing after heat

treatment
Shot peening ○ Os the shot inspection standard approved (until 11 days before delivery of trial product)? Not Applicable

Processing after heat

Shot peening Is the required quality of shot comprehended? Not Applicable
treatment
Processing after heat
Shot peening Is there a qualification system of shot operator? Not Applicable
treatment
Processing after heat
Shot peening Is there a list of qualified shot operator? Not Applicable
treatment

Secondary supplier Shot peening ◎ Is a secondary supplier recorded? Not Applicable

Secondary supplier Shot peening ◎ Is it designed so that a position processed by secondary supplier is assured by primary supplier? Not Applicable

Secondary supplier Shot peening ◎ Is a product delivered from secondary supplier inspected? Not Applicable

Secondary supplier Shot peening ◎ Is a communication route made clear when any trouble occurs? Not Applicable

Overview of secondary supplier's process

Location:

Number of employees: persons

Involved sales: /month　　　　　　　　％

Major suppliers: ①　　　　　　　　　　　②　　　　　　　　　　　　　　③

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◎：MUST, ○：WANT
Checking result
Checking item Process in detail Criticality Checking item
1st prototype Trial production Production

○ Where can it be found when foreign material mixes in? NOK Mixup Possibility Observed
◎ When foreign material mixes in, can the history be tracked? NOK
○ Is acceptability judgment criterion specified for initial product checking? OK
◎ Are wrinkle and lap inspected after cleaning by magnetic- pawder examination? OK
Processing ◎ Are the measurement point and frequency of intermediate product specified by standard, etc? OK
(forging) Is it ensured that handling after pressing and intermediate packaging style do not cause nick
○ and deformation? NA
Lubricating process ○ Is a portion that requires hardness free from bonderizing process and forging skin? NA
Workmanship ○ Is hardness inspected after processing? NOK Hardness Not Checked
check ○ Are the wrinkle, scratch, and crack inspected? OK MPI Checked
Is there a work standard available? (Are the temperature, heat treatment time, and hardness
◎ specified?) NOK
Is the timing specified and operated for evaluating temperature variation due to position in the
◎ furnace? NOK
Is the timing specified and operated for evaluating hardness variation due to position in the
Equipment control ◎ furnace? NOK
◎ Is a rule specified and operated for checking and calibrating the precision of hardness gage? OK
◎ Is hardness measurement included in inspection item? OK
◎ Is a rule specified for remedy when hardness is NG? NOK
◎ Is the layout of products specified? NOK There is possibility of tempring Process Skip
◎ Is the equipment checked daily? NOK
Gas organization ○ Is raw material gas and conversion condition controlled? OK
◎ Does the sensor function properly (measurement for controlling Cp value)? OK
Atmosphere control OK
◎ Is a rule specified for calibrating the sensor?
system
◎ Is double check applied by measurement of TP hardness, etc? NOK
○ Is the work surface area controlled for stabilizing the atmospheric density? OK
Atmosphere ○ Is there a rule available for adjusting the atmospheric density by work charging amount (surface area?) OK
concentration ◎ Is the measurement by Cp sensor properly fed back to the atmospheric control? OK
○ Are the control result and value of atmosphere recorded? NOK
○ Is the treatment time controlled properly by the configuration and surface area of work? OK
Treatment time
○ Is the control result of treatment time recorded? OK
○ Is an appropriate treatment temperature set for requirement? OK
Treatment OK
◎ Is a treatment temperature measured?
temperature
◎ Is the setting position of thermocouple specified? OK
◎ Is the quantity of charging controlled? NOK
Heat treatment Packaging style
◎ Is a criterion set for loading mixed with other parts? NOK
Is the temperature controlled on the outer surface of work in consideration of radiant heat
Heating system
○ (when control is on-off system)? na
Quenching ◎ Is the quenching temperature measured? OK
temperature ◎ Is the criterion of temperature set and controlled? OK
Quenching oil ◎ Is the temperature of quenching oil measured? OK
temperature ◎ Is the criterion of quenching oil temperature set and controlled? OK
Quenching time ◎ Is the retention time in quenching oil set and controlled? OK
○ Are the type and brand of quenching oil specified? OK
◎ Is quenching oil used at the temperature recommended by its type and brand? OK
Quenching oil
○ Can the deterioration of quenching oil be measured? OK
◎ Are the criterion and frequency set for changing or refilling quenching oil? NOK
Quenching
Is cooling oil set to ensure layered flow, and is thin material placed vertically?
packaging style ○ NA
Oil agitation condition ◎ Is the agitation condition of quenching oil set? NOK
◎ Is the tempering temperature set conforming to the function? OK
○ Is time controlled from quenching to tempering? NOK
Is it ensured that tempering is not at a temperature within tempering fragility area (250 -
Tempering 450C)? OK
◎
temperature
◎ Is the tempering temperature measured? OK
◎ Is the tempering temperature measurement device calibrated? OK
◎ Is the tempering temperature measurement result recorded? OK
◎ Is the tempering time measured? NOK
Treatment time
◎ Is the measurement result of tempering time recorded? OK
Packaging style ◎ Is the upper and lower limit set for charging quantity? NOK
○ Is there a special inspection system (N1000-N1) available when starting mass production? NOK
Are the shipment inspection method and judgment criterion made clear (function, appearance,
◎ and measurement)?
NOK
◎ Is process capability taken into consideration for sampling quantity of in-process inspection? NOK
Is acceptance inspection carried out for supplier's parts? (Are the items and inspection quantity
◎ reasonable?)
OK

○ Is there a control criterion available for new process and new function parts (net of assurance)? NA
Inspection system
◎ Is the history of engineering change made clear? (System) NA
◎ Is the latest engineering change incorporated to the parts? OK
○ Is the detail of quality failure comprehended of similar parts in the past? NA
○ Is the measure against quality failure incorporated of similar parts in the past? NA
◎ Are trouble item and person in charge of action schedule specified? NA
◎ Is the system of initial control established? NA
Is there a qualified metallic heat treatment engineering technician? OK
◎ Is there equipment available for nondestructive flaw detection? NOK
◎ Is there a nondestructive flaw detection work standard available? NOK
◎ Are the inspection frequency and position indicated on the work standard? NOK
Is a nondestructive inspection operator trained by a qualified person? Is there a training record
◎ available? NOK
Is it ensured that fabric gloves such as cotton gloves are not used (visual mistake in
○ inspection)? NOK
Flaw detection
Inspection after
Heat treatment Does nondestructive flaw detection cover 100%? (If not, what kind of criterion is applied to
○ sampling?) NOK
◎ Is the inspection record of nondestructive flaw detection kept (prototype and trial production)? NOK
◎ Is a flaw detected over all the surface of work? NOK
◎ Are any corrective measure and correction route specified when flaw detection result is NG? NOK
◎ Is there a defective part disposal rule available? Is it appropriate? NOK
Does the inspection equipment match with inspection method (Quality standard) requirement
◎ item? NOK
◎ Can the jig and gage set to the parts easily? NOK
Measurement
◎ Is it ensured that no unmeasurable item of parts is found? NA
device control
○ Is the replacement frequency specified for hardness reference piece? OK
○ Is daily check carried out on hardness reference piece? OK
○ Is a daily check record of hardness measurement equipment left on check sheet, etc? OK
○ Can a specimen be adjusted appropriately for observing structure? NOK
○ Is there a system available for storing actual inspected product? OK
Micro stracture Is there an evaluation criterion of micro structure available on the line? NOK
◎
inspection
○ Is there any organization recording device available? NOK
◎ Is there any corrective action specified when organization NG occurs? OK
◎ Is the acceptability judgment criterion of surface hardness made clear? OK
◎ Is the result of hardness measurement stored? NOK
Hardness Is a measurement position specified (both surface and section)? NOK
◎
inspection
◎ Is a measurement position observed? NOK
◎ Is there any corrective action specified when hardness NG product is found? NOK
Overview of secondary supplier's process
Location:
Number of employees: persons
Involved sales: /month　　　　　　　　％
Major suppliers: ①　　　　　　　　　　　②　　　　　　　　　　　　　　③
 7／8
　　Quenching and tempering process check sheet　　1/3

◎：MUST, ○：WANT
Checking result
Checking item Process in detail Criticality Checking item
1st prototype Trial production Production
Processing Where can it be found when foreign material mixes in? NOK Mixup Possibility Observed
○
(forging)
Processing
(forging) ◎ When foreign material mixes in, can the history be tracked? NOK
Processing
(forging) ○ Is acceptability judgment criterion specified for initial product checking? OK
Processing
(forging) ◎ Are wrinkle and lap inspected after cleaning by magnetic- pawder examination? OK
Processing
(forging) ◎ Are the measurement point and frequency of intermediate product specified by standard, etc? OK
Processing Is it ensured that handling after pressing and intermediate packaging style do not cause nick
(forging) ○ and deformation? NA
Processing
Lubricating process Is a portion that requires hardness free from bonderizing process and forging skin?
(forging) ○ NA
Processing Workmanship
Is hardness inspected after processing?
(forging) check ○ NOK Hardness Not Checked
Processing Workmanship
Are the wrinkle, scratch, and crack inspected?
(forging) check ○ OK MPI Checked
Is there a work standard available? (Are the temperature, heat treatment time, and hardness
Heat treatment Equipment control
◎ specified?) NOK
Is the timing specified and operated for evaluating temperature variation due to position in the
Heat treatment Equipment control
◎ furnace? NOK
Is the timing specified and operated for evaluating hardness variation due to position in the
Heat treatment Equipment control
◎ furnace? NOK
Heat treatment Equipment control ◎ Is a rule specified and operated for checking and calibrating the precision of hardness gage? OK
Heat treatment Equipment control ◎ Is hardness measurement included in inspection item? OK
Heat treatment Equipment control ◎ Is a rule specified for remedy when hardness is NG? NOK
Heat treatment Equipment control ◎ Is the layout of products specified? NOK There is possibility of tempring Process Skip
Heat treatment Equipment control ◎ Is the equipment checked daily? NOK
Heat treatment Gas organization ○ Is raw material gas and conversion condition controlled? OK
Atmosphere control OK
Heat treatment ◎ Does the sensor function properly (measurement for controlling Cp value)?
system
Atmosphere control
Heat treatment Is a rule specified for calibrating the sensor?
system ◎ OK
Atmosphere control
Heat treatment Is double check applied by measurement of TP hardness, etc?
system ◎ NOK
Atmosphere OK
Heat treatment ○ Is the work surface area controlled for stabilizing the atmospheric density?
concentration
Atmosphere
Heat treatment Is there a rule available for adjusting the atmospheric density by work charging amount (surface area?)
concentration ○ OK
Atmosphere
Heat treatment Is the measurement by Cp sensor properly fed back to the atmospheric control?
concentration ◎ OK
Atmosphere
Heat treatment Are the control result and value of atmosphere recorded?
concentration ○ NOK
Heat treatment Treatment time ○ Is the treatment time controlled properly by the configuration and surface area of work? OK
Heat treatment Treatment time ○ Is the control result of treatment time recorded? OK
Treatment OK
Heat treatment ○ Is an appropriate treatment temperature set for requirement?
temperature
Treatment
Heat treatment Is a treatment temperature measured?
temperature ◎ OK
Treatment
Heat treatment Is the setting position of thermocouple specified?
temperature ◎ OK
Heat treatment Packaging style ◎ Is the quantity of charging controlled? NOK
Heat treatment Packaging style ◎ Is a criterion set for loading mixed with other parts? NOK
Is the temperature controlled on the outer surface of work in consideration of radiant heat
Heat treatment Heating system
○ (when control is on-off system)? na
Quenching OK
Heat treatment ◎ Is the quenching temperature measured?
temperature
Quenching
Heat treatment Is the criterion of temperature set and controlled?
temperature ◎ OK
Quenching oil OK
Heat treatment ◎ Is the temperature of quenching oil measured?
temperature
Quenching oil
Heat treatment Is the criterion of quenching oil temperature set and controlled?
temperature ◎ OK
Heat treatment Quenching time ◎ Is the retention time in quenching oil set and controlled? OK
Heat treatment Quenching oil ○ Are the type and brand of quenching oil specified? OK
Heat treatment Quenching oil ◎ Is quenching oil used at the temperature recommended by its type and brand? OK
Heat treatment Quenching oil ○ Can the deterioration of quenching oil be measured? OK
Heat treatment Quenching oil ◎ Are the criterion and frequency set for changing or refilling quenching oil? NOK
Quenching
Heat treatment Is cooling oil set to ensure layered flow, and is thin material placed vertically?
packaging style ○ NA
Heat treatment Oil agitation condition ◎ Is the agitation condition of quenching oil set? NOK
Tempering OK
Heat treatment ◎ Is the tempering temperature set conforming to the function?
temperature
Tempering
Heat treatment Is time controlled from quenching to tempering?
temperature ○ NOK
Tempering Is it ensured that tempering is not at a temperature within tempering fragility area (250 -
Heat treatment
temperature ◎ 450C)? OK
Tempering
Heat treatment Is the tempering temperature measured?
temperature ◎ OK
Tempering
Heat treatment Is the tempering temperature measurement device calibrated?
temperature ◎ OK
Tempering
Heat treatment Is the tempering temperature measurement result recorded?
temperature ◎ OK
Heat treatment Treatment time ◎ Is the tempering time measured? NOK
Heat treatment Treatment time ◎ Is the measurement result of tempering time recorded? OK
Heat treatment Packaging style ◎ Is the upper and lower limit set for charging quantity? NOK
Inspection after
Heat treatment
Inspection system ○ Is there a special inspection system (N1000-N1) available when starting mass production? NOK
Inspection after Are the shipment inspection method and judgment criterion made clear (function, appearance,
Heat treatment
Inspection system ◎ and measurement)?
NOK
Inspection after
Heat treatment
Inspection system ◎ Is process capability taken into consideration for sampling quantity of in-process inspection? NOK
Inspection after Is acceptance inspection carried out for supplier's parts? (Are the items and inspection quantity
Heat treatment
Inspection system ◎ reasonable?)
OK

Inspection after
Inspection system ○ Is there a control criterion available for new process and new function parts (net of assurance)? NA
Heat treatment
Inspection after
Heat treatment
Inspection system ◎ Is the history of engineering change made clear? (System)
NA
Inspection after
Heat treatment
Inspection system ◎ Is the latest engineering change incorporated to the parts?
OK
Inspection after
Heat treatment
Inspection system ○ Is the detail of quality failure comprehended of similar parts in the past?
NA
Inspection after
Heat treatment
Inspection system ○ Is the measure against quality failure incorporated of similar parts in the past? NA
Inspection after
Heat treatment
Inspection system ◎ Are trouble item and person in charge of action schedule specified? NA
Inspection after
Heat treatment
Inspection system ◎ Is the system of initial control established? NA
Inspection after
Heat treatment
Inspection system
Is there a qualified metallic heat treatment engineering technician? OK
Inspection after
Flaw detection
Heat treatment ◎ Is there equipment available for nondestructive flaw detection? NOK
Inspection after
Flaw detection
Heat treatment ◎ Is there a nondestructive flaw detection work standard available? NOK
Inspection after
Flaw detection
Heat treatment ◎ Are the inspection frequency and position indicated on the work standard? NOK
Inspection after Is a nondestructive inspection operator trained by a qualified person? Is there a training record
Flaw detection
Heat treatment ◎ available? NOK
Inspection after Is it ensured that fabric gloves such as cotton gloves are not used (visual mistake in
Flaw detection inspection)?
Heat treatment ○ NOK
Inspection after Does nondestructive flaw detection cover 100%? (If not, what kind of criterion is applied to
Flaw detection
Heat treatment ○ sampling?) NOK
Inspection after
Flaw detection
Heat treatment ◎ Is the inspection record of nondestructive flaw detection kept (prototype and trial production)? NOK
Inspection after
Flaw detection
Heat treatment ◎ Is a flaw detected over all the surface of work? NOK
Inspection after
Flaw detection
Heat treatment ◎ Are any corrective measure and correction route specified when flaw detection result is NG? NOK
Inspection after
Flaw detection
Heat treatment ◎ Is there a defective part disposal rule available? Is it appropriate? NOK
Inspection after Measurement Does the inspection equipment match with inspection method (Quality standard) requirement
Heat treatment device control ◎ item? NOK
Inspection after Measurement
◎ Can the jig and gage set to the parts easily?
Heat treatment device control NOK
Inspection after Measurement
Heat treatment device control ◎ Is it ensured that no unmeasurable item of parts is found? NA
Inspection after Measurement
Heat treatment device control
○ Is the replacement frequency specified for hardness reference piece?
OK
 8／8
Inspection after Measurement
Heat treatment device control ○ Is daily check carried out on hardness reference piece? OK
Inspection after Measurement
Heat treatment device control ○ Is a daily check record of hardness measurement equipment left on check sheet, etc? OK
Inspection after Micro stracture
Heat treatment inspection ○ Can a specimen be adjusted appropriately for observing structure? NOK
Inspection after Micro stracture
Heat treatment inspection ○ Is there a system available for storing actual inspected product? OK
Inspection after Micro stracture
Heat treatment inspection ◎ Is there an evaluation criterion of micro structure available on the line? NOK
Inspection after Micro stracture
Heat treatment inspection ○ Is there any organization recording device available? NOK
Inspection after Micro stracture
Heat treatment inspection ◎ Is there any corrective action specified when organization NG occurs? OK
Inspection after Hardness
Heat treatment inspection ◎ Is the acceptability judgment criterion of surface hardness made clear? OK
Inspection after Hardness
Heat treatment inspection ◎ Is the result of hardness measurement stored? NOK
Inspection after Hardness
Heat treatment inspection ◎ Is a measurement position specified (both surface and section)? NOK
Inspection after Hardness
Heat treatment inspection ◎ Is a measurement position observed? NOK
Inspection after Hardness
Heat treatment inspection ◎ Is there any corrective action specified when hardness NG product is found? NOK
Overview of secondary supplier's process
Location:
Number of employees: persons
Involved sales: /month　　　　　　　　％
Major suppliers: ①　　　　　　　　　　　②　　　　　　　　　　　　　　③