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PROCESSTABLEE-Electrocoat,,,,

"Allrequirementsgivenbelowaresubordinatetocustomerspecificrequirements.

Thecustomermayhaveadditionalrequirements,e.g.,inspectiontesting,greaterfrequencies,etc.Whenperformingthejobaudit,theauditorshallverifycoaterisconformingtocustomerrequirements.",,,,

,,,,,

Item#,"Related

CSAQuestion#",Category/ProcessSteps,Control,Monitoring

1.0,,Pre-ElectrocoatPaintApplicationPartAppearance,,

E1.1,1.42.11,Incomingpartsareinspectedforcleanlinessand/oruniformphosphatecoating(whenphosphateisused).,Manual,PerControlPlan/LogSheet(1perhour)

2.0,,ElectrocoatLaboratory,,

E2.1,2.14,Laboratoryequipmentiscalibratedandingoodworkingorder.,N/A,

E2.2,2.14,"Laboratorystandardsandreagentsareproperlystored,labeled,andnotexpired.",N/A,

E2.3,2.14,"Laboratoryrecords,internalandexternal,arefiledandaccessibleforreview.",N/A,PerControlPlan/LogSheet(1/shiftminimum)

3.0,,ElectrocoatTank,,

E3.1,"1.4

2.11

2.12","Bathparameters(pH,conductivity,solidcontent,temperature,voltage)arecheckedandadjusted.",Automatic/Manual,PerControlPlan/LogSheet

E3.2,"1.4

1.6

2.11

2.12",Linespeedsetupischecked.,Automatic/Manual,PerControlPlan/LogSheet

E3.3,"1.4

2.11

2.12",Linespeedisverified.,Manual,Once/weekminimum

E3.4,"1.4

2.11

2.12","Thereiscirculationanditismonitored.(flowmeter,pressuregage)",Automatic/Manual,PerControlPlan/LogSheet(1/shiftminimum)

E3.5,"1.4

2.11

2.12",Bagfilterpressuresaremonitored.Bagschangedwhenpsidifferential.>5-10PSI.,Automatic/Manual,PerControlPlan/LogSheet(1/shiftminimum)

E3.6,"1.4

2.11

2.12",Flowdirectionischecked(formonorailsystem).,Manual,PerControlPlan/LogSheet(1/shiftminimum)

E3.7,"1.4

2.11

2.12",Flowovertheweirischecked.,Manual,PerControlPlan(1/shiftminimum)

E3.8,"1.4

2.11

2.12",Bathischeckedformicrobialcontamination.,Manual,PerControlPlan/LogSheet(1/perweekminimum)

E3.9,"1.4

2.11

2.12",IncomingDI/ROwaterischeckedforcleanliness.(conductivity),Automatic/Manual,PerControlPlan/LogSheet(1/shiftminimum)

E3.10,"1.4

1.17

2.11

2.12",Paintracksarebeingmaintained.,Automatic/Manual,Asneeded

E3.11,"1.4

1.17

2.11

2.12",Thereisapaintrackmaintenanceschedule.,Manual,Required

E3.12,"1.4

1.17

2.11

2.12",Thereisatankcleanupschedule.,Manual,Required(1/yearminimum)

4.0,,AnolyteSystem,,

E4.1,"1.4

2.11

2.12",Theanolytesolutionisbeingcontrolledwithintherequiredconductivitylimits.,Automatic/Manual,PerControlPlan/LogSheet(1/shiftminimum)

E4.2,"1.4

2.11

2.12",Theconductivityreadingontheanolytetankhasbeenconfirmedinthelaboratory.,Automatic/Manual,PerControlPlan/LogSheet1/week

E4.3,"1.4

2.11

2.12",ThepHoftheanolytesolutionhasbeenchecked.,Automatic/Manual,PerControlPlan/LogSheet(1pershift)

E4.4,"1.4

2.11

2.12",Anodeshavebeeninspected.,Manual,PerControlPlan/LogSheet(1persixmonths)

E4.5,"1.4

2.11

2.12",Theanolytesolutionisbeingcirculatedtoeachcell.,Automatic/Manual,PerControlPlan/LogSheet(1/shiftminimum)

E4.6,"1.4

2.11

2.12",Dumpandcleanscheduleforanolytebeingmaintained.,Manual,PerControlPlan/LogSheet

E4.7,"1.4

2.11

2.12",Amperagedrawhasbeencheckedoneachanode.,Automatic/Manual,PerControlPlan/LogSheet

5.0,,Rectifier,,

E5.1,"1.4

1.6

2.11

2.12",Thepropervoltageisbeingusedfortheloadsize.,Manual,perEquip.Mfg.

E5.2,"1.4

2.11

2.12",Therampuptimetofullvoltagehasbeenverified.,Automatic/Manual,PerControlPlan/LogSheet(1pershift)

E5.3,2.10,Thereisasafetybeacontoalertpersonnelwhensystemisenergized.,,

E5.4,"1.4

1.17

2.11

2.12",Therippleoftherectifierhasbeencheckedbyanapprovedelectrician.,Automatic/Manual,PerControlPlan/materialsupplier

6.0,,RinseSystem,,

E6.1,"1.4

2.11

2.12",Immersionrinsetanksareoperatingattheproperlevelsandtanksarebeingagitatedcorrectly.,Automatic/Manual,PerControlPlan/LogSheet(1/shiftminimum)

E6.2,"1.4

2.11

2.12",Thereissufficientpermeatesuppliedtotherinse.,Automatic/Manual,PerControlPlan/LogSheet(1/shiftminimum)

E6.3,"1.4

2.11

2.12",ThepHandconductivityoftherinsehavebeenrecorded.,Manual,PerControlPlan/LogSheet(1/shiftminimum)

E6.4,"1.4

2.11

2.12",Thereismicrobialtestingofrinses.,Manual,PerControlPlan/materialsupplier

E6.5,"1.4

2.11

2.12",Theultrafiltersareoperatingatproperpressuresandbagfiltersarebeingused.Whatsizebags?,Automatic/Manual,PerControlPlan/LogSheet(1/shiftminimum)

E6.6,"1.4

1.17

2.11

2.12",Rinseshavebeenclean

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