GM-1927-16a-Welding-Process-Audit

Auditor:Date:Page1ofSupplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatsfactoryNotSatisfactoryNeedsImmediateAction1WhatistheWeldingtransferbeingused(Pulse,ShortArc,Spray,etc)WPSshouldhaveprocesslisted2Whatweldwireclassficationandwiresizeisbeingused?WPSshouldhaveinfolisted3Howistheweldingbeingcontrolled?(robotspeed,feed-rateofwire,amperage,etc.)YesorNo4Areallcomponentsofyourweldsystem(powersources,robot,wire-feeder,gas-flowetc.)calibrated?Ifyes,howisitdone?Frequency?YesorNo5IsthereaPreventiveMaintenance(PM)planontheRobotsandWeldingSystem(PowerSource,Feeder,WeldingTorch,ReamerUnit,etc)andisitfollowed?ReviewallDocumentation6Aretheresparepartsidentifiedandcurrentlyinsupply?Suggestedforlongleadtimeitemsonly7CheckweldwirefeeddeliverysystemVerifycomponentsandfeeddriverolltensionersetting.Feedandmeasureatimedwiresegment,orreadcalibratedindependentwiredriventachometer1Aresamplesizeandcheckfrequencyforeachweldoperationsreasonable?Theapprovedweldverificationfrequenciesarebasedonweldcounts,locationsandrisk2Isthereadetailedcross-sectioningprocedureavailable?Standardcross-sectioningproceduresshouldbepostedinweldlabandsubmittedinplan3Isthereevidencethatthecross-sectioningprocedureisfollowed?Samplesordigitalimagesshouldbeavailableforreviewduringtheaudit4Arethemeasuringdevicesforthecross-sectioningcalibrated?Calibrationrecordsforallmeasurementdevicesshouldbetrackedandavailable5Areproperoperatorinstructionsavailableforeachweldoperation?ThisshouldbefollowedaspartofthePPAPvaluestreamprocedure6AreStandardizedWorkinstructionsdetailedtoruntheweldcellproperly?ThisshouldbefollowedaspartofthePPAPvaluestreamprocedureGMProcess/PartSpecificAuditProcessSpecificAudit:14058WeldAuditVersion:InitialReleaseIssueDate:June30,2009AssessmentSection1:WeldSystemAuditQuestionsSection2:QualitySystemAuditQuestions7DoesthesupplierincludeweldrepairinthePFD,PFMEA,ControlPlan,WorkInstruction&isitacceptable?WeldrepairproceduresareclearlyidentifiedwithintheGMAW14058specificationandshouldbepostedatthecell8Aretheoperatorsproperlytrained?Dotheyunderstandtheinstructions?RefertotheQSBstandardforoperatortrainingmatrix9AreMasterPartsavailableatthelinesideforoperatortoreviewSuppliertoconductaLayeredAuditwithinthedepartment10DoesthesupplierhavesufficientchecksinplaceatGP12forweldprocesses?GP12areashouldbespecificforweldsamples,pictorial,specificationandinstructions1WhatistheShieldingGasmixturerate(eg:90/10%ofAr/Co2)Reviewdocumentation2Howisyourshieldinggasmixed?InhouseviagasmixerorbottledgasfromlocalSupplyhouse3Howisthepressureoftheshieldinggasmonitored?Alarmwhenpressuredropsbelowacertainthreshold?Reviewdocumentation4Whoisincontroloftheshieldinggasmixer?IsitaMaintTech,aWeldTechoraWeldingEngorotherEng5Aretherecheckstovalidateshieldinggassettingsandifsowhenandbywhom?Reviewdocumentation1Verifyweldingtorchandmountingbracketsaretightandincorrectposition.ValidatedviaaTCPcheckprogramwas/createdandvalidated2HowaretherobotsTCP(ToolCenterPoint)maintainedandisthereaPMfortherobotsTCPMinonceaMonth3Ifaroboticcrashoccurs,howistherecoveryhandled?IsaTCPverificationdonepriortoweldingnextpart?Reviewdocumentation4Whatisthefrequencyofchangeoftheweldtip?Isitbeingdonepertheprescribedfrequency?Reviewdocumentation1WheretheWeldProcessControlPlancallsforSPC,isthedataproperlyrecorded?GMPPAPrequirementifshowninStatementofRequirementsSection3:ShieldingGasAuditQuestionsSection4:Error-ProofingAuditQuestionsSection5:SafetyWeldsandEquipment2AretheUpperControlLimits(UCL)orLowerControlLimits(LCL)currentrelativetolatestdesign/materialthicknesschange?Doesthedatamakesense?RefertoAIAGstatisticalmanual,revisionrequiredbaseontoolingimprovements3Areoutofcontrolpointsnotedwiththecorrectiveactiontaken?PPAPrequirementspecifiescorrectionsrequiredforFULLAPPROVAL4Areallsafetydevicesoperatingproperlyandcheckeddaily?Mechanicalorelectricaldevicesshouldbetestedpriortostartingtheproductionweldcell5Aredocumentsavailableforreview?LayeredAuditProcess1AreGlobalWeldSpecificationsfortheirweldprocessesbeingfollowed?GenerallydiscussedinthePDTorearlyGateReviews2DoesthesupplierknowwheretogetthelatestinformationonGMSupplyPower?ManufacturingsectionorsearchControls,Robotics,Welding3DoesthesupplierhavethelatestGMweldPFMEAforthoughtstarters?GMWeldPFMEAMay07isavailablefromyourSQE,locatedinthesharedrive4ArethesuppliersusingtheDDWREADACROSSformatforeachassembly?ThisstrategyshouldbeusedforallGMapplications,showninGM1927DateVersionSection6:SummaryQuestionsAuditOwner:ChangeHistoryChangeSummaryProcessPerformanceSUPPLIERACTIONPLANREPORTRev.71/7/02SupplierStartDate:LocationRev.Date:DunsGradDate:CommodityProgram:Preparedby:GGreen-TaskCompletedonTimeYYellow-TaskMayBeLateRRed-TaskisLateWWhite-TaskRe-Timed,NoStatusBBlue-TaskStatusisIncorrect/NotUpdatedOnTrack(BoldBox/NoColor)TOTALTOTAL00ITEMPriorityGroupACTIONITEMACTIONLEADERDATEOPENEDTARGETCLOSEDATEACTUALCLOSEDATELASTUPDATE123456COUNTERMEASURES1#REF!2#REF!3#REF!4#REF!5#REF!6#REF!7#REF!8#REF!9#REF!10#REF!11#REF!12#REF!13#REF!14#REF!15#REF!16#REF!1