GM-1927-16a-Tooling-Setup-Process-Audit

QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateAction1(Fit/Formissues)PARTSPECIFIC:Ensureouterformsofpatterns,molds,diesaretoprintforprofilecallouts(reviewbonustolerances)VerifyPPAPpartstoproductionpartsamples(Beginning,middle,last)ofprocessrun.SurfacescanusingDCC/CMMorlaserunitshouldbeoverlaidtomathdatatoverify.Ifaproblemisfound,thenfocusonfeature/formimpactedbyallformsofaction,slides,lifters,pins,cores,sleeves,etc.2(Impingementriskstofunctionalityofpart)PARTSPECIFIC:Ensurecriticalzonesonpartsthatcancauseimpingementareproperlymarkedonboundarysamples.Verifythroughlayoutofpartthatcriticalzones,impactingfit/form/functionofunitareproperlylinkedtoreleasedmathdataatcorrectengineeringlevelsandshownonaboundarysampleorpicturefortheoperator.Ifgageisused,verifyGR&Rresults/certificationandtestsamples.3(Longtermdurability,crackingduetofatigue,unitleaksandpoorsealing)PARTSPECIFIC:Anyevidenceofvariationduetodiedesign,castingcelllayout,manual-vs.-automatic?Wallstockverifiedforsubsurfaceporosityorjustsurface?Reviewdiepenetrantprocedure,X-rayifusedforverifyingfolds,cracksandporosity.Verifyprocedurestoreacttoexcessiveporosityandtimetoreact.VerifythatLotholdsort/releaseeffectivetocaptureN/Cparts4(Impingementriskstofunctionalityofpart/Appearanceconcerns)TOOLINGFOCUS:Ensurerepairsdoneon(sandcast)moldsandcoresorejectorcoresandcavities(injectionmolding)orOperator/Helper,upperandlowersides(diecast)aredoneproperlytooriginalmathdata.VerifythatallsurfacesareproperlypatchcutandblendedtooriginalmathoflatestECL.Layoutshouldgobeyondpatchedsurfacetoensuremismatchisnotpresent.Startwithpartlayouttocomprehendifadditionalworkisnecessary.5(Impingementriskstofunctionalityofpart/Appearanceconcerns)TOOLINGFOCUS:Ensureouterformsofpatterns,moldsaretoprintforprofilecallouts(reviewbonustolerances)Includesallformsofaction,slides,lifters,pins,cores,sleeves,etc.Ensuretheyhavenotwornbeyondthemathsurfacelower/upperprofilelimits.VerifyusingaDCC/CMMorlaserunittocheckiftoolingwearismonitoredbytoolingmaintenanceandcriticalarea'sthatimpactfit/form/functionarecrosscheckedtomastermathdatausedinconstructionoftheformonthedie/moldforPPAP.6(Processingrelatedissues,surfaceimperfectionsandfunctionalityofparts)TOOLINGFOCUS:Ensuretoolingisproperlycleanedduringoperationandeveryeffortismadetoensuresurfacesarenoterodedfromtheuseofgrinders,sanders,brass/copperchiselsinarea'spronetobuildupVerifythathandtoolsinuseatthestationhavewarningspostedforimproperuse.VerifythattrainingdescribesimpacttopartfortheoperatorAssessmentCase/Cover/Bracket/HousingCastings//FocusCriticalZonesonpartCase/Cover/Bracket/HousingMachining//FocusCriticalZonesonpartPreparedbyJimChicosky2020/6/22Page1QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionAssessment1(Impingementriskstofunctionalityofpart)PARTSPECIFIC:Ensureinnerandoutermachinedfeaturesoncases,covers&bracketsthatcanimpactanyformofactionaremonitoredoverlifeoftoolingVerifycutterpathiscorrecttomathandformtolerancesby:1.Checkingtoolingoffsets2.Checkmachinedsurfaceon1stpieceandattoolchange3.Verifyproperholdersandextensionsareinusetoprotectfromexcessivedeflection3.Inspectfixturingsurfacesarefreefromdamage,dents/dingsorhaveexcessivechipbuildup.2(Impingementriskstofunctionalityofpart)PARTSPECIFIC:Ensurecriticalzonesonpartsthatcancauseimpingementareproperlymarkedonboundarysamples,picturespostedinthemachiningcellVerifythroughlayoutofpartthatcriticalzones(KPC,PQC,DR,etc,impactingfit/form/functionofunitareproperlylinkedtoreleasedmathdataatcorrectengineeringlevels.(Multiplecavities)Ensureallcavitiesinusearelistedandverifiedonthelayout.Reviewcapabilitydataforallcriticaltargetswithavailablevariabledataasrequired.3(Lossofrequiredwallstock,mountingsurfacesand/orintendedrigidityofpart)PARTSPECIFIC/REWORK:Ensurerepairsinvolving(partinglinesdropped/offsetforcleanup)machiningoncovers,housingsandbracketsaredoneproperlytooriginalmathdatawithinallowablemin/maxtolerancingfromprintVerifythatallsurfacesareproperlypatchcutandblendedtooriginalmathoflatestECL.Layoutshouldgobeyondpatchedsurfacetoensuremismatchisnotpresent.Ahigherlevelofinspectionshouldbedoneananyreworkedparts,scrutinizeprocessifinuse.4(Setuprelatedissuesrequiringimprovedcontrols/qualifyingerrorsincastings,weldments,forgingsimpactingmachiningtargets)TOOLINGFOCUS:Ensurecutterpathstomachinesurfacesareoffsetproperlywithcutters,neworregrindcutterscangreatlyimpactformandblendingquality.Verifythatarea'spronetomismatchproblemsduetocomplexcutterpathsaremonitoredwiththeuseofboundarysamples,inspectionofcriticalzonesusingDCC/CMMorlaserscanned.ControlPlancheckfrequencymustbeadequatetocatchsurfaceloss.Throughdaily/weekly/monthly/annuallylayoutsdependingontherequirementsofthetoolsteelandrelatedprocess.5(Dimensionalconcernsduetotoolingoffsets)TOOLINGFOCUS:(Note:Toolsetupeitherlineside,orservicetocompany.)EnsurecuttersetupmachinesareusingtheproperoffsetsforgivencutterinspecificoperationCriticaltoballendmil