AAM-2-081 Cleanliness Procedure 02-02-2010

1.0 PURPOSE: 1.1 To create a procedure to determine the amount of sediment contained within components that make up final assemblies produced by AAM. This procedure will be used as an audit to drive continuous improvement for components supplied by AAM as well as components purchased from outside suppliers.  All AAM facilities as well as outside suppliers will follow this procedure to qualify component cleanliness to the requirements on the engineering drawing.  2.0 SCOPE: 2.1 This procedure is applicable to Material Specification and Process Standard documents of AAM. 2.2 This procedure applies to all AAM manufacturing facilities finished parts prior to assembly. 2.3 This procedure applies to all finished parts supplied to AAM by outside suppliers prior to shipment. 3.0 REFERENCE: 3.1 AAM Corporate Quality Policy Manual. 3.2 AAM-9-112 - Control of Quality Records. 3.3 ISO/TS16949:2009, ISO 9001:2008, Section 4.2.4 – Control of Records. 3.4 ISO/TS16949:2009, ISO 9001:2008, Section 7.5.1 – Control of production and service provisions. 4.0 RESPONSIBILITIES: 4.1 Functional head of Corporate Materials Engineering and/or designee. 4.2 The Chemical Commodity Management team or designated plant support personnel at AAM facilities will check individual part sediment and statistically chart the results once a month for each part just prior to assembly 4.3 External suppliers must check individual parts for sediment and statistically chart the results once a month just prior to shipping parts to AAM. 4.4 Quarterly,  AAM SQA and/or designated personnel may check sediment levels on a randomly chosen part from an external supplier. 5.0 GENERAL: 5.1 Revisions to this procedure require written approval of the manager(s) or designee(s) of the responsible Product Engineering department(s). 5.2 To verify latest document revision level, contact the facility/department quality system coordinator. 5.3 All Corporate quality system procedures and job instructions will be controlled electronically.  Any hard copies designated as controlled documents shall be identified by one of the following methods:  special paper (colored or textured), markings, or stamps.  All other copies shall be considered uncontrolled. 5.4 Quality system procedures and/or job instructions shall be published when guidelines are required or when responsibilities involve the interaction of more than one group. 6.0 PROCEDURE: 6.1 Component Sediment Testing/Analysis                                           The Chemical Commodity Manager at AAM facilities or plant designated department will perform the following procedure, statistically chart the results, and distribute data as specified for each specific AAM internally supplied part number. For parts supplied by an outside supplier, the supplier will be required to put a program in place to cover the monthly testing as defined below for all parts supplied to AAM to assure that the level of part sediment conforms to the established AAM criteria. Each AAM facility SQA Department or appropriate personnel may from time to time perform the following procedure on randomly chosen parts supplied to AAM by an outside supplier. 6.1.1 Collect parts from their respective dunnage located at the point of assembly.  A minimum of 5 parts are to be run to determine the average amount of particulate, with the exception of carriers.  A minimum of 3 carriers are to be run to determine the average amount of particulate. NOTE:  Although dunnage cleanliness requirements are not listed in this specification, appropriate dunnage cleaning procedures must be carried out by the respective plant. 6.1.2 Select a 300-μm and 10-μm polyester filter and an aluminum oven tray. The filter should be equivalent to part numbers 305-041-8000 (300-μm) and 325-041-8000 (10-μm) as supplied by Great Lakes Filter. 6.1.3 Place the 300-μm and 10-μm filters in an oven tray and heat in an oven for ? hour at 150?F.  Remove the filters from the oven and allow them to cool in a dessicator for 30 minutes. 6.1.4 Weigh the dried 300-μm and 10-μm filters and record to the nearest 0.1mg. 6.1.5 Place the part to be analyzed for sediment levels in a suitable container that has been wiped clean with a lint free cloth and is large enough to hold the part. 6.1.6 Using a continuous stream spray bottle, rinse the entire part with enough fresh washing fluid to remove all dirt and or particulate on the part. The recommended fluid shall be mineral spirits or a suitable solvent with a flash point around 150?F.                                                                                       NOTE:  The use of mineral spirits and other solvents poses a potential safety hazard, therefore personnel must wear safety glasses with side shields and rubber gloves when working with these materials.  All washing and rinsing must be performed using a properly ventilated hood. 6.1.7 All surfaces of parts that contact lubricants such as oil and grease shall be completely rinsed.  Some examples of areas on parts to be rinsed are listed below: