DISASSEMBLY / CLEANING (STANDARD)
AREA SIZING
122. Designated areas for disassembly and cleaning are isolated for airborne debris - SR
Good:
Disassembly/cleaning areas separate/isolated from rebuild/assembly areas
Debris and noise are prevented from being transferred to assembly area
Acceptable:
Disassembly is close to assembly but debris is not transferred to assembly area
Review shop layout, distances, walls, doors, curtains, positive air flow, and debris controls
123. Areas sized for anticipated product/volume - SR
Good:
Clear path to all bay equipment, staging, and components. Work space adequate
for multiple technician´s to have a clear path to work on and around the
component
General shop review
STAGING-BASKETS / RACKS / STANDS
124. Only income staging. No outgoing staging - SR
Good:
Cleaned parts are immediately moved from this area
General shop review
125. Clean parts are immediately protected from dust/contamination – policy enforced – SR
Good:
Cleaned parts are immediately protected from dust / contamination
General shop review
126. Major castings staged on pallets on floor - SR
Good:
No parts, assemblies, or components are staged directly on the floor – smaller
parts are on racks / carts
General shop review
127. Open access to all staged parts and components - SR
Good:
Parts and components staging allows for accessibility by moving <2 components
/ baskets / racks
General shop review
CONTROL DOCS & CHECKLISTS
128. Disassembly docs and checklists - SD
Good:
Disassembly documentation and checklists are being utilized
Provide checklists for review. W/O audit check
129. Control checklist include: 1) Owner ID 2) Revision ID/date 3) User signature - PD
Good:
One owner responsible for updates. Revision dated, technician signature
W/O audit check. Review checklist used in bay for information in print
DISASSEMBLY / INSPECT PROCESS
130. Parts inspection / evaluation process - SR
Good:
Area designated and includes inspection / measuring tools
General shop review
131. Submit SIMS report for every defect in parts and/or workmanship - PD
Good:
SIMS reports are completed on all failures to provide effective feedback to
dealer technical services, quality teams, and Caterpillar service engineering
functions
Review documented programs. Provide sample SIMS reports that demonstrate failure reports:
1) for warranty and non-warranty, 2) occurring or corrected during rebuild, installation, and inservice
132. Reused major parts marked for hours/history - SD
Good:
When parts are marked per a policy, the code must identify the reuse event and
the service hours on part since the last reuse event.
Acceptable:
Policy exits to NOT mark parts
Provide documented marking policy. W/O audit check. Review process with technicians
CLEANING PROCESS
133. Dedicated parts cleaning staff - SR
Good:
Parts cleaning staff limited and trained for consistency. Technicians not
performing role
Review cleaning personnel staffing
134. Inspection after cleaning - SR
Good:
Lead person provides continuous general parts condition checks and random indepth inspections. Documented feedback given to cleaning staff
Identify who is lead person over cleaning function
135. Rust inhibitor applied after washing - SD
Good:
Rust inhibitor applied through an injector, during automatic rinse cycle
Acceptable:
Rust inhibitor applied manually
Provide PI specifications. Review parts washing inhibitor system/process/limitations
136. CC supplies – caps/covers/plastic wrap - SR
Good:
Caps, plugs and plastic wrap identified. Stored in easily accessible area protected
from the environment. Cleaned and readily available for shop personnel. Used
immediately after cleaning
General shop review
SHOP EQUIPMENT
137. Bridge & jib cranes are properly rated and cover critical work bay areas - SR
Good:
Capacity > largest anticipated loads. Jib cranes must cover component,
workbench and stating areas
Acceptable:
Areas are only fully covered by a community bridge crane
Hook height must be higher than anticipated components and lifting devices (bridge, etc.).
Cranes must have power travel (bridge cranes) and hoists
138. Work bench sized for needs, effective workmanship, includes vise, soft top - SR
Good:
Benches are covered with a durable material to protect sensitive parts. Material
used does not absorb oil and provides protection for sensitive parts
Acceptable:
Bench top is easy to clean, clean and smooth
One bench should meet requirements in area
139. Disassembly stands for all components - SR
Good:
Dedicated / purpose built support stands are used to keep components off the
floor. Does not allow component to shift during process.
General shop review
140. All tools/equipment maintained clean on daily basis-in-bay - PD
Good:
Person responsible for daily tool / equipment cleanliness
Who is responsible for daily maintenance?
141. Adequate cleaning equipment-filtered wash basins and bulk solvent tanks - SD
Good:
4-micron final filer being used. 15-25-micron bag filter on drain. Solvent
maintained at ISO -/16/13. Water based solvents must be visible clean. Note:
This standard is directed at cleaning equipment used for final cleaning
Provide filter spec sheet if not identified on body
142. Airborne debris controlled - SR
Good:
Contaminants from the disassembly process are not found in the assembly area.
Buffing performed over capable downdraft tables with side / back guards.
Cabinet washers have power evacuation system with timers to prevent early
door opening after wash cycle
General shop review
143. Chemical storage is in protected area - SR
Good:
Chemical supplies are managed by parts department. Staged and inventoried in
bays by dedicated resource. Technicians do not retrieve / manage supplies
General shop review of chemicals
144. Oil control grid - SR
Good:
Grid used for component drain and catch drips as removed parts drip / drain.
Large enough to control oil spill “tracking” in CRC
Acceptable:
Portable wheeled carts used. There should be no waste fluid spillage during
removal, transfer and disposal
Review disassembly area. Must cover area large enough to catch drips as parts / components
are removed and drain parts / components before loading into cleaning baskets
145. General floor and task lightning at workbench, specific inspection lightning - SR
Good:
General bay (ceiling and side lights): 750-1100 lux (70-100 ft candles)
General task (bench – parts inspect): 1100-1550 lux (100-150 ft candles)
Specific (supplement inspection lights): 1550-2200 lux (150-200 ft candles)
Measure incident light – non reflected light is measured. Note: these light intensities should be
met unless local lightning codes do not allow them
POWER CLEANING
146. Capable automatic washers - SD
Good:
Washing system sized for 95% of product. High pressure / flow cabinet washers
for effective / consistent performance or automated acid tank wash system.
Fresh water rinse wand for after – wash flushing to get all internal passages
cleared of debris
Acceptable:
Low – flow washer with good maintenance resulting in a clean component
Provide washer (s) power, pressure and flow. Inspect nozzles for size (0.025”). Review rinse /
flush methods. Review parts cleanliness immediately out of washer.
147. Effective wash baskets and racks - SR
Good:
Baskets / racks hold parts dirtiest areas against spray nozzles. Enough baskets /
racks for anticipated product volume
Review cleaning area
148. Minimum manual cleaning - SR
Good:
Manual washing only for parts vulnerable to damage
Review cleaning area and process
149. Consistent gasket removal before/after power washing - SR
Good:
Contaminants from removal process are not found in assembly area. Parts are
rinsed following the use of a metal conditioning disk
Review process with cleaners. Review parts for excess “grinder” wear that will increase leaks
and reduce part life
150. Scuff & buff performed for final cleaning/inspection - SR
Good:
Remaining paint / chips “feathered out” and corrosion removed as final step
before inspection for reuse / installation
Review parts for paint chips, corrosion and over-cleaning