GM-1927-16a-Leak-Test-Process-Audit

Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateAction1Areleaktestfixturesealsandsensorscheckedafterapre-determinednumberofrejects?(Alarmlimits)ReactionplanwhenAlarmLimitsarereached.Jobinstructions.SiteProcedures/ControlPlan.Reviewlogs/Worksheets.2Isleaktestingequipmentmeetingratedcycletimes?ReviewEngineeringdocumentsandcontractrequirements.SiteProcedures/ControlPlan.Reviewlogs/Worksheets.(ProcessandQuality)3IsthereadedicatedpneumaticorhydrauliclinetoconducttheLeaktest?Isthelinesharedbymultiplemanufacturinglines?Controlsinplace(flow-meters,Pressuregagesetc.)toensureappropriatesupplyofleaktestmedia.Identifydropinpressures.4Areleaktestemployeestrained(supervisors,operators,jobsetters,inspectors,repairpersonetc)?Monthlyreviewsandemployeesign-off.Reviewemployeetrainingrecords&verifyemployee/managementsign-off5Istherestandardizedworkforeachleaktestoperation?Reviewjobinstructions.SiteProcedures/ControlPlan.Reviewworksheetsandverifyvisualsareinplace.6Doemployees'understandthejobinstructionsSiteProcedures/ControlPlan.Observeemployeeperformingtasksandvalidatewithjobinstructions.7Aremachinery,equipment,andgagescalibrated/visuallyinspected?Frequency?(Startofshift,mid-shift,priortochangeover'sandendofshift)Reviewlogs/Worksheets.8Isthereaprocesstorungreenandredmasterpartsthrougheachleaktestoperation?Aretheycertified?Iscertificationrelativetocurrentproductanduptodate?Frequency?(Startofshift,mid-shift,priortochangeover'sandendofshift)Reviewlogs/Worksheets.Reviewcertificationrecords.Comparecurrentproductagainstin-stationmasters.9Doesthemasterparthaveadefinedleakagerate?ReviewsiteProcedures/ControlPlan.Reviewalllogs/Worksheets.(Maint.Safety,ProcessandQuality)ProcessControlGMProcess/PartSpecificAuditProcessSpecificAudit:LeakTestAssessmentVersion:2.0IssueDate:15Sep20091of12Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionGMProcess/PartSpecificAuditProcessSpecificAudit:LeakTestAssessmentVersion:2.0IssueDate:15Sep200910Aretheleakagelimitsandtestmethod(over/underpressure)agreedwithGMEngineeringandpartofthe(KeyProductCharacteristics)inGMdrawings?ReviewEngineeringdocumentsandcontractrequirements.SiteProcedures/ControlPlan.Reviewlogs/Worksheets.(ProcessandQuality)11Isoperatorworkareaandtestfunctionareacleanandfreeofpartsanddebris?Dirtinwork-stationcaninterferewiththeseals/air-linesetc.SiteProcedures/ControlPlan.Visuallyobserveworkstationandsurroundingarea.12Isproperpersonalprotectivegearbeingutilizedbyoperator?JobInstructions.Visuallyobserveworkstationandsurroundingarea.13Arescrappartscorrectlyidentifiedandplacedinredscrapbins?Isthereainspectionlogsheet?SiteProcedures/ControlPlan.Visuallyobserveworkstationandsurroundingarea.14Istestmediafiltered(Air,Fluid,etc)?Sizeoffilters/changeofFiltersfrequency/ControlPlan/PFMEA/Visualverification.ReviewPMlogs/MediaTestlogs.15Isthereaprocesstocheckchemistry(PH,buffer,mediaconcentration,bacteriaetc.)oftestmediaandwhereisitdocumented?Jobinstructions.SiteProcedures/ControlPlan.Reviewalllogs/Worksheets.16Arerustpreventivelevelswithincontrollimits?ReviewsiteProcedures/ControlPlan.Reviewalllogs/Worksheets.(Maint.Safety,ProcessandQuality)17Areout-of-specificationconditionsand/orchemicaladjustmentsnoted?ReviewsiteProcedures/ControlPlan.Reviewalllogs/Worksheets.(Maint.Safety,ProcessandQuality)18Arerustpreventivelevelswithincontrollimits?ReviewsiteProcedures/ControlPlan.Reviewalllogs/Worksheets.(Maint.Safety,ProcessandQuality)19Areout-of-specificationconditionsand/orchemicaladjustmentsnoted?ReviewsiteProcedures/ControlPlan.Reviewalllogs/Worksheets.(Maint.Safety,ProcessandQuality)2of12Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionGMProcess/PartSpecificAuditProcessSpecificAudit:LeakTestAssessmentVersion:2.0IssueDate:15Sep200920Howdoyoutreatrejectsfromleaktest?(testthemtwiceagainbeforeintrointotheprocess?)Ifintroducedbackintotheprocess/value-stream,whatistheverification&re-introductionpoint?ReviewsiteProcedures/ControlPlan.Reviewalllogs/Worksheets.(Safety,ProcessandQuality)21Areanycomponentssalvagedfromtear-down/re-workedparts?(Itishighlyrecommendedtoscrapallseals,gaskets,o-rings,valvesetc.thatfunctionasLeakpreventionsi.e.One-timeuseonly)Doallre-builtpartsundergothesameleak-checkatthemainprocesslinewithcertified/trainedoperators?VisualObservation22Arethereanyspecialhandlingandorcleaningprocessofre-workedpartsrequired?ReviewsiteProcedures/ControlPlan.Reviewalllogs/Worksheets.(ProcessandQuality)23Whatisthemaximumnumberatimesapartcanbetestedbeforeitisscrapped?ReviewsiteProcedures/ControlPlan.Reviewalllogs/Worksheets.(ProcessandQuality)24Areallacceptedparksmarkedwithapermanentsignorcouldthemarkingberemoved?ReviewsiteProcedures/ControlPlan.Reviewalllogs/Worksheets.(ProcessandQuality)25Istheleakte