GM-1927-16a-Coating-Process-Audit

Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateAction1Areemployeestrained(supervisors,operators,jobsetters,inspectors,repairpersonetc)?Monthlyreviewsandemployeesign-off.Reviewemployeetrainingrecords&verifyemployee/managementsign-off.2Istherestandardizedworkforeachleaktestoperation?Reviewjobinstructions.SiteProcedures/ControlPlan.Reviewworksheetsandverifyvisualsareinplace.3Isthereawrittenspecificprocesscontrolplanforallactiveprocess?ReviewProcessControlPlanandIdentifyallofthemanufacturingsteps.(Includingcycletime,temperature,etc)4Isthereadedicatedandqualifiedexpertonsite?5Isworkareacleanandfreeofoutsideelements?Reviewplantcleanlinessandhousekeepingtoensuretheworkenvironmentisfreeofcontamination.(seeContaminationProcessAudit)6Isthereanairrefreshmentandairqualitymonitoringsystemstoavoidvapourpollutionofthebaths?7Arethereproperprotectionsagainsthazardouschemicalandenviroments?8AreallprocessflownessbeingmanagedwithPLCcontrol(onepiecefollow)?9ArePMrecordsuptodate?ReviewPMlogsandworksheets.10Isthereavisualcheckinplacetoverifymaterialcertifications,packslip,andlabelpartnumbers?Reviewcustomerbarcodeid,certificateofanalysisandeachbin/container.GMProcess/PartSpecificAuditProcessSpecificAudit:CoatingAssessmentVersion:1.0IssueDate:24Jun09General1of10Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionGMProcess/PartSpecificAuditProcessSpecificAudit:CoatingAssessmentVersion:1.0IssueDate:24Jun0911Isthereasysteminplacetoreviewandaddresscustomerconcerns?Thefacilityshalldocumentcustomerconcernsalongwithactionplans.12Aremachinery,equipment,andgagescertified?AreGMSprinciplesbeingused?(Gagesmarkedinoptimumrange?)AnnualCertificationby3rdParty.ReviewCertificationrecords.Visuallyinspectgages.13Whattypeoftestmethodisutilized?Reviewrequirementforcoatingthickness,corrosionresistance,adhesion,curing,color,andgloss.1Isthereaprocessinplacetoverifycorrectpartsareloaded?Reviewerrorproofingprocess.2Isthereaprocessinplacetoensurepartcarryingfixturesprotectsunitagainstdamageand/ormutilation?ReviewcarryingfixturePM.3Areconveyorsandtransmissionsystemsingoodformandworkproperly?welldesignedandsuitablefortheparts?4Arecarryingfixturesstoredproperly?5Isthereaprocessinplacetoensurepartcarryingfixturesprovidesforadequatecoating?6Isthereaprocedureinplaceforappropriateloadingofunits?Reviewdrawingsand/orspecificationstoensureadequateloadingangles,directions,andflatness.7Istheloadingprocessdesignedfortraceability?Loading2of10Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionGMProcess/PartSpecificAuditProcessSpecificAudit:CoatingAssessmentVersion:1.0IssueDate:24Jun091Ismaterialconcentrationverified?Reviewlotnumbers,controlplansandlogsheets.2Aretemperaturesandprocesstimesrecordedandverifiedperprocessrequirement?Reviewtemperaturegage.3Isthereaprocessinplacetoverifycleaningsolutionsassuitableforremovingallprocesssoilsasdemonstratedbywaterbreak?Reviewlotnumbers,controlplansandlogsheets.4Isthereaprocessinplacetoensureadequatepressure/agitation?5Isthereaprocessinplacetoverifycycletimetoensureappropriateexposuretopre-treatment?Reviewcontrolplan,logsandworksheets.6Iscorrosioninhibitorconcentrationregularlychecked/inspected?Reviewcontrolplan,logsandworksheets.7Isthereaprocessinplacetoverifycoatingweight,crystalsize,andfluorideconcentration?Reviewcontrolplanandcustomerrequirement.8Whatisthedumpscheduleforcleaning,rinsing,andsealing?Reviewchemicalmanufacturerguidelines.9Isthetemperatureintheoil-dirtremovalbathunitundercontroli.e.within+/-5°Candisasrequired?Pre-treatment3of10Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionGMProcess/PartSpecificAuditProcessSpecificAudit:CoatingAssessmentVersion:1.0IssueDate:24Jun0910Isoil-dirtremovaldonebybasicandacidicbathingsandintermediatewashingsandifnecessarymanualremoval?11Isthereafinalrinseandisitmonitoredforpresenceofbacteria(forplasticsubstrate)?Reviewcontrolplan/logsheets.12Isthereanappropriateprocessforverifyingadequatesealingcoverage?Reviewcustomerspecifications.1Whatisthefrequencyforairtemperaturemonitoringandcontrol?Reviewcontrolplan/logsheets.2Isthereanappropriateproceduretoensureeffectivedryness?Revieweachlot.3Areovensetpointsandprocesstimerecordedandverifiedasmeetingtheprocessrequirments?Reviewcontrolplan/logsheets.1Whatistheproceduretoverifycoatingiscorrectandmeetscompositionalrequirments?Reviewcustomerspecifications.2Whatistheprocesstomonitorgunpressure?ReviewPMlogsandworksheets.3Whatistheprocesstomonitorappropriatecoverageoftheparts?ReviewControlplan4Whatistheprocesstomonitorboothhumidity?ReviewcontrolplanandlogsheetDryOffCoatingSpray4of10Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQu