CQI-9 Heat Treat Audit at PairGears: Ensuring Gear Quality & Control

Introduction

Founded on engineering excellence, PairGears specializes in precision gear manufacturing for agricultural machinery, trucks, construction machinery, and electric vehicles. To guarantee every gear meets the highest automotive and industrial standards, PairGears implements a comprehensive heat treat system assessment in full compliance with AIAG CQI-9 “Special Process: Heat Treat System Assessment”. This blog delves into our CQI-9 framework, process controls, and the benefits delivered to our clients.

1. Why CQI-9 Compliance Matters

• Process Consistency: CQI-9 ensures all heat treatment parameters (temperature, atmosphere, timing) are documented and controlled.

• Risk Mitigation: Through structured FMEA and Control Plans, potential failure modes are anticipated and addressed.

• Customer Confidence: Demonstrable adherence to AIAG CQI-9 and IATF 16949 builds trust with OEMs and Tier 1 suppliers.

_{External References:}

_{• AIAG APQP & Control Plan Manual: https://www.aiag.org/quality/apqp}

_{• SAE J1739 FMEA Standard: https://www.sae.org/standards/content/j1739_201006/}

2. Key Elements of Our Heat Treat System Assessment

1. Management Responsibility & Quality Planning

• Dedicated heat-treat specialists and documented APQP processes.

• Regular revision of PFMEA to reflect current quality status .

2. Control Plans & Process Specifications

• Comprehensive Control Plans cover every step from material receipt to final dispatch.

• Computer-protected “recipes” define critical parameters (e.g., temperature ±15 ℃, atmosphere dew point ±0.05 CP) .

3. Equipment Validation & Monitoring

• Temperature Uniformity Surveys (TUS): Annual and post-maintenance furnace surveys ensure ±10 ℃ uniformity.

• Thermocouple Calibration: Quarterly external calibration and daily in-process checks.

• Real-time data logging with alarm thresholds and 24-hour review by qualified personnel.

4. Data Collection & Continuous Improvement

• Trend analysis of key process parameters and product characteristics.

• Closed-loop corrective actions guided by Control Plan deviations and audit findings.

3. Advanced Heat Treatment Technologies

At PairGears, we employ a full spectrum of heat treat processes, including:

• Carburizing & Carbonitriding: Deep case hardening for high-load applications.

• Neutral Hardening & Tempering: Precise core hardness with minimal distortion.

• Vacuum Heat Treatment: Oxidation-free, high-precision hardening ideal for aerospace-grade gears.

• Induction Hardening: Localized surface hardening for shafts and pinions.

Explore our services in depth on our gear manufacturing page.

4. Quality Metrics & Client Benefits

• Hardness Uniformity: ≥95 % of parts within ±1 HRC of target hardness.

• Dimensional Stability: Post-treat flatness and cylindricity deviations ≤0.02 mm.

• Yield Improvement: 20 % reduction in rework scrap rates since CQI-9 implementation.

• Traceability: Full batch genealogy, QR-coded work orders, and digital records available on request.

Clients benefit from predictable performance, extended gear life, and minimized warranty claims.

5. Suggested Visuals for Publication

1. Heat Treat Furnace Interior: Demonstrate rack loading and thermocouple placement.

2. TUS Setup Photo: Array of sensors inside furnace chamber.

3. Data Dashboard Screenshot: Real-time parameter trends and alert notifications.

4. CQI-9 Audit in Action: Engineers reviewing PFMEA and control plans.

Conclusion

By rigorously following AIAG CQI-9 standards, PairGears ensures that every gear we produce meets the highest benchmarks for quality, reliability, and performance. To learn more about our CQI-9 compliant heat treatment solutions or to request a detailed process audit, please contact us.

Should you have any questions or require further assistance, please do not hesitate to contact our engineer: ben@pairgears.com.