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AC7126/1 REV.

B
Issued 2010-03
AUDIT CRITERIA
Revised 2016-08
161Thorn Hill Road
Warrendale, PA 15086-7527 Superseding AC7126/1 Rev. A

TO BE USED ON AUDITS STARTING ON OR AFTER 4-DEC-2016

Nadcap
AUDIT CRITERIA FOR HOLEMAKING

1. SCOPE

This checklist is to be used as a supplement to PRI AC7126 for


Suppliers seeking accreditation for the manufacturing of Holes deemed
critical to aerospace design and safety.

2. GENERAL INSTRUCTIONS

Note: the questions in this checklist contain no EC content.

NA (Not Applicable) answers to questions will be permitted only to the


extent defined in the checklist.

The number of job audits depends on the scope of the audit. See the
Audit Handbook for additional details. In all cases a minimum of 2 job
audits are required.

2.1 Audit Scope

The scope of this audit includes AC7126 and the manufacturing of


holes.

2.2 Methods

Methods are the sub-scopes selected for this audit. The method is to
be indicated in each job audit. The methods for AC7126/1 include
Holemaking, Holemaking with Process Monitoring, Abrasive Flow Post
Finish, Jig Grinding Post Finish, and Hone Post Finish.

PRI operating procedures provide that "This report is published by PRI to advance the state of technical, engineering, and quality
sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent
infringement arising there from, is the sole responsibility of the user."

PRI values your input. To provide feedback on this document, please contact the appropriate commodity staff engineer.
(Contact information is located at http://www.eauditnet.com under “Contact Us”.)
Copyright 2015 Performance Review Institute. All rights reserved.
t-frm-15 06-Jan-2015
PRI AC7126/1 Revision B -2-

NOTE: Holemaking with Process Monitoring applies when the Supplier


is requesting qualification to a specific Subscriber requirement for
Process Monitoring. Some Subscribers have certain Classes within
their controlling specifications that require the use of specific process
monitoring systems (e.g. power monitors, speed monitors, etc.), and
have requirements for the use and calibration of those systems. In
those cases the audit questions related to "Process Monitoring" are to
be measured against those Subscriber requirements (see Subscriber
controlling specifications and the Handbook for details).

In the absence of such requirements, Supplier equipment may still


include process monitoring systems. For example, coolant flow
monitors are common on modern machining centers. If those systems
are not intended to satisfy a Subscriber's requirements for Process
Monitoring, select only "Holemaking" as the method.

3. DEFINITIONS

3.1 Holemaking

The manufacture of holes by conventional machining as a special


process. Holes may be round or shaped in profile and may be through
or "blind". Holes are typically produced using a rotating tool, including,
but not limited to, drills, mills, reamers, and single-point boring
tools. Unless otherwise specified by the Customer, the holemaking
operation includes any associated feature such as edgebreaks*,
counterbores, and spotfaces. Features such as shaft bores that are
produced by turning are not considered holes, although the initial
operation (e.g. gundrilling) may be controlled as a holemaking
operation. In such cases consult the handbook or Customer
documentation for guidance as to which features and operations are to
be included under this audit. *The auditors need to check Customer
requirements to verify if a separate edge treatment audit is also
required.

3.2 Holes

Except where otherwise described by the Customer, a "hole" includes


any associated edgebreaks, counterbores, and spotfaces. Where
these associated features are produced on the same machine as the
hole, audit questions apply to each operation/cut. If they are produced
at separate workstations (including handbench), repeat applicable
questions at each workstation.

3.3 Additional Definitions

For definitions and interpretations see the Conventional Machining as a


Special Process (CMSP) Task Group Audit Handbook. This and other
pertinent data can be found and downloaded from eAuditNet under
Resources/Documents/Public Documents.
PRI AC7126/1 Revision B -3-

4. JOB AUDIT

NOTE: Fill out as much information as applies. Put not applicable if the
data does not exist. Do not include any information marked (EC) if the
part is export controlled and note it as such. Customer/Subscriber,
Order #, Lot #, and Part Number are required

4.1 Customer Requirements

Job Details

Select the Job’s status

Completed or In Process _______________

Date job was completed if a historical job. _______________

Select the Method audited (from the following):


Holemaking
Holemaking with Process Monitoring
Abrasive Flow Post Finish _______________
Jig Grinding Post Finish
Hone Post Finish

Select whether the Supplier indicated that the part audited was Export
Controlled (ITAR/EAR):
Yes, Export Controlled
Did not indicate Export Controlled

Informational: If the job audit does not cover the “Holemaking with
Process Monitoring” Method, please check to indicate if the equipment
used for the job audit was capable of process monitoring and if it was in
use during the job audit.

If it is in use but not in the scope, the questions on Process Monitoring


do not need to be answered

Complete the following information.

Job Audit Properties

Customer _______________

Subscriber _______________

Unique Work Order # or Lot # _______________

Quantity _______________
PRI AC7126/1 Revision B -4-

Serial Number of audited part(s) _______________

List the details of the processes and equipment audited _______________

Job Identification

Drawing # / Part Number / Rev. _______________

Purchase Order Number / Rev. _______________

Operation Sequence Number _______________

Class (if applicable) _______________

Specification/Operator/Requirements _______________

Specification/Rev _______________

Operator Identification _______________

List source of holemaking requirements (Purchase Order, drawing, _______________


fixed/frozen process documentation, internal specification, etc.)

Flow Down

Have quality and technical requirements been flowed down? YES NO

CAG (Compliance Assessment Guidance): As it relates to CMSP,


Review the Purchase Order, specification, any other Customer
quality/technical requirements documents and verify that the flow down
is correct on all paperwork (routers, Work Instructions, etc.) through the
process. This question also includes anyapplicable Purchase Order
amendments.

4.2 Process Approvals SECTION NA

NA applies if process approvals are not required by the Customer.

Does the process approval document (technical plan, manufacturing YES NO


plan, data sheet, etc.) contain all of the information per Customer
requirements?

Is there objective evidence of Customer approval for the holemaking YES NO


process(es) being used?
PRI AC7126/1 Revision B -5-

Are all features controlled by Customer engineering requirements YES NO


accounted for in the process approval document?

CAG: Verify that all controlled features defined by customer


requirements (drawing/PO/etc) have been submitted for approval

Are all operations performed on the controlled features accounted for YES NO
in the process approval document(s)?

CAG: Verify that all operations used by the Supplier to produce


controlled features have been documented/ approved. Give special
consideration to operations not performed as part of machining. For
example, manual deburr, handbench, and separate edgebreak
operations.

4.3 Document Control

Is the process being performed per the current revision of applicable YES NO
requirements?

CAG: This question applies to the approval document, for example a


technical plan or FMP/PX 6041-20. The current revision is defined by
the appropriate flow down documents and may include drawings,
Customer specifications/requirements and/or industry specifications.

Are the Work Instructions at the workstation the current same revision YES NO
and do they match the approved process, and does that planning have
all changes properly incorporated?

CAG: The process described in workstation documentation must match


the Customer approved document. Planning shall be current and have
all changes properly incorporated. Temporary changes to workstation
documentation must be properly approved.

Are changes to the process proposed by the Supplier approved by the YES NO NA
Customer and design authority if required prior to incorporating the
change?

CAG: NA applies if no changes have been made or if approval for


specific changes has been delegated to the Supplier by the Customer.

Work Instruction General

Are Work Instructions detailing each operation available at each work YES NO
station and do they show evidence of approval, revision level and date?

CAG: The work instructions themselves may not be approved by the


Customer but must be traceable back to the Customer approved
document.

Are the Work Instructions being reviewed before starting the machining YES NO
process and is the operation performed per the Work Instruction?
PRI AC7126/1 Revision B -6-

Are all process steps that are performed included in the Work YES NO
Instructions?

Do the Work Instructions indicate that the operation is frozen to the YES NO
extent required by the Customer?

Do the Work Instructions include all of the information required by the YES NO NA
Customer, including all required documents?

CAG: NA applies if the Customer has no requirements controlling the


content of the work instructions.

Work Instruction Adequacy

Do Work Instructions identify specific features (or the entire operation) YES NO
to which the Customer requirements apply?

Are all of the controlled features detailed on the Customer’s drawing or YES NO
other Customer flowdown accounted for in the work instruction?

CAG: Verify that all controlled features defined by Customer


requirements have been flowed down and that no controlled features
on the drawing/PO/etc. were omitted.

Do Work Instructions direct that approved process parameters may not YES NO
be overridden (or are locked-out)?

CAG: If the process in question has been approved by the Customer at


one value or range, it must be run at that value or range even if the
Customer’s specification allows a wider range.

Do Work Instructions describe all controlled cutting tools and abrasives YES NO
such that the operator can verify they match the approved process?

CAG: This requirement may be met by a physical description of all


controlled features (including geometry, material, and coating, if any) or
by reference to a drawing, catalogue, crib or other number/code that
uniquely describes the tool.

Do Work Instructions include change intervals or wear criteria for each YES NO
controlled cutting tool or abrasive?

Does the Work Instruction establish a manufacturing YES NO


sequence/chronological order?

Are Customer stock removal requirements documented in the Work YES NO NA


Instruction and performed?
PRI AC7126/1 Revision B -7-

CAG: The requirement for stock removal need not be explicitly stated in
the work instruction as long as the process described achieves the
required material removal. For holemaking, stock removal refers to
radial stock removed between roughing and finish machining. NA
applies if stock removal requirements are not specified by the
Customer.

Do Work Instructions indicate the cutting fluid flow rate and/or pressure YES NO NA
if required by the Customer?

CAG: NA applies if flow rate and/or pressure requirements are not


specified by the Customer.

Is there evidence that the tool change point or wear criteria for each YES NO NA
controlled cutting tool or abrasive has been approved by the Customer
during substantiation, if required?

CAG: NA applies if approval is not required by the Customer.

Work Instruction Holemaking Details

For each individual process in making a given hole:

Do the Work Instructions describe the layout and positioning of coolant YES NO NA
delivery nozzle(s) so that it can be set-up repeatedly for each cutting
tool and machining stage?

CAG: The operator needs to be furnished with enough information so


that if the coolant delivery system is disturbed it can be re-set with
sufficient accuracy to assure that the machining process is not affected.
Through the tool coolant and fixed non-adjustable nozzle systems
satisfy this requirement. Boilerplate for similar operations is
acceptable. NA is allowed if coolant is not used. This does not apply to
Abrasive Flow and it may not apply to Jig Grind.

Do the Work Instructions specify the machines approved for use and is YES NO
this consistent with Customer requirements?

CAG: Machine may be identified by make, model and manufacturer


serial number or Supplier local reference number. The intent is that the
Work Instructions clearly indicate which machine(s) is to be used. Refer
to the Customer requirements to determine if work instructions may
apply to multiple machines.

Do Work Instructions (may refer to a revision controlled CNC program) YES NO


list values or ranges for all parameters required to run the process?

Do the Work Instructions detail how to set up cutting tools? YES NO


PRI AC7126/1 Revision B -8-

CAG: If the Supplier has specific Customer requirements, they need to


be in the work instructions. If there are no specific requirements, then
there must be information to allow repeatable set-up of the tooling. The
instructions should be adequate to identify collets, tool holders, etc.,
and their assembly.

Do the Work Instructions include all work holding devices and fixtures YES NO NA
where required by the Customer?

CAG: NA applies if there are no Customer requirements.

For hand bench operations on controlled features, do Work Instructions YES NO NA


describe the devices (e.g. air motor), cutting tools and abrasives
approved for processing the features?

CAG: NA applies if there are no hand bench operations performed on


controlled features.

Other Documentation

Is the shop traveler (including equivalent paper or electronic record) YES NO


used to reflect sequence of operations, inspection points, identification
of the individual(s) performing the work and date properly completed?

CAG: Properly means that the paperwork is filled out or acknowledged


electronically as it is supposed to be as required either by the Customer
or by the Supplier’s own rules.

Work Instructions for Process Monitoring SECTION NA

NA If the scope does not include holemaking with process monitoring,


the section is NA.

Do Work Instructions for process monitoring communicate the process YES NO


limits/alarm level(s)?

Are alarm limits (e.g. power, torque, force, flow, etc.) developed YES NO
consistent with Customer requirements?

Have the process limits/alarm level(s) been approved per the Customer YES NO
requirements?

Do the Work Instructions state how to arm the process monitoring YES NO
system and how the operator is to react to an alarm condition?

Is there evidence that alarm events are properly managed per YES NO NA
Customer requirements?

CAG: NA applies if no events have occurred.


PRI AC7126/1 Revision B -9-

4.4 Personnel Qualification

Is there evidence that the personnel received the required training YES NO
before performing controlled operations?

CAG: Some Customer training requirements apply to personnel other


than operators, e.g. process engineers, inspectors, procurement
personnel, tool control personnel, quality engineers, maintenance, etc.
Some Customers have specific requirements regarding training
content, see specific Customer requirements.

Is the training for each person involved in the process current per the YES NO
required interval?

CAG: This applies to Customer and/or Supplier required training.

4.5 Equipment

Equipment Adequacy

Is the process running on an approved machine? YES NO NA

CAG: NA applies if the Customer does not require the process to be


run on an approved machine.

Does the machine have the capability to interrupt the machining YES NO NA
operation when a process parameter exceeds a defined range if this
capability is required by the Customer?

CAG: Specific requirements for machine response exist within


Customer specifications. Examples include coolant flow/pressure,
force, power, speed, etc.
NA applies if this is not required by the Customer.

For processes that require cutting fluid flow or pressure sensing, is YES NO NA
there a separate sensor for the through-spindle cutting fluid branch
(where used)?

CAG: NA applies if coolant sensing is not required, through-spindle


coolant is not used, or is used exclusively (flood lines disabled).

Are all gages and process monitoring equipment identified as to their YES NO
calibration status and current as per local procedure?

For process monitoring, does the time threshold of the process YES NO NA
monitoring system meet Customer requirements?

CAG: “Time threshold” refers to the length of time that a parameter has
to stay above a threshold in order for the system to consider it an alarm
and take action.
NA applies if the Customer has no requirements for time threshold.
PRI AC7126/1 Revision B - 10 -

Equipment Qualification

Are all periodic machine and monitoring system qualifications current? YES NO NA

CAG: Customer requirements may include visible qualification status


on the machine, re-qualification intervals, etc.
NA applies if there are no functions requiring periodic qualification per
Customer requirements.

Have all machine and process monitor calibrations been performed YES NO NA
after any maintenance related to those systems or monitored machine
functions?

CAG: NA applies if Customer does not have requirements for machine


and monitor calibrations or if no maintenance of this type has been
performed on the machine.

Equipment Maintenance

Has the preventive maintenance program been completed as per YES NO


schedule and are records available to verify completion?

4.6 Cutting Fluid SECTION NA

Section is NA only if the operation is approved to be run without cutting


fluid.

Does the cutting fluid in use match the documented cutting fluid YES NO
including approval by the Customer if approval is required?

Does the cutting fluid delivery method, match the documented process YES NO
including approval by the Customer if approval is required?

CAG: Customer requirements may include flow rate and/or pressure;


when pressure is specified it is measured with static pressure.

Has the Supplier performed cutting fluid maintenance per their YES NO
documented procedure?

Is there a system in place to signal the operator of a significant YES NO NA


interruption in the cutting fluid flow during the machining operation per
Customer requirements?

CAG: An interruption may be partial reduction of flow or pressure in


addition to complete cessation, reference Customer or internal
requirements.
NA applies if there are no Customer requirements on the amount of
fluid flow.
PRI AC7126/1 Revision B - 11 -

Is there an automated system capable of interrupting the process in YES NO NA


case of loss of cutting fluid flow or pressure if required by the
Customer?

CAG: NA applies if there are no Customer requirements.

4.7 Process Performance

Is the correct version of the NC program in use? YES NO NA

CAG: NA applies if the process being audited is not NC program


controlled.

Do the parameters in use match the approved values or ranges? YES NO

CAG: Only parameters such as cutting speed, feed rate, tool change
points, need be verified. Dimensional commands are not to be verified.
If the process is CNC, verify values in the NC program.

Are parameters in use within Customer requirements, if applicable? YES NO NA

CAG: NA applies if the Customer does not have any requirements that
limit parameters. The auditor only needs to verify parameters that have
Customer requirements.

Is the use of Speed and Feed override controls consistent with the YES NO NA
Customer requirements?

CAG: NA applies if the Customer does not have any requirements that
pertain to the use of override controls.

Is all shop-level documentation properly completed? YES NO

CAG: shop-level documentation may include routers, inspection


reports, etc.

Is there evidence that local procedures for handling Special Cause YES NO
Events are known to the operator?

CAG: Verbal verification from the operator(s) that is in agreement with


the procedures is acceptable.

Is there objective evidence that any special cause event was reported, YES NO NA
documented, and evaluated per Supplier and any Customer
requirements?

CAG: NA applies if no events have occurred.


PRI AC7126/1 Revision B - 12 -

Does the actual process match the approved process? YES NO

CAG: The approved process includes frozen/fixed process and any


documented Customer allowed process changes. The scope of this
question can include process steps or process sequence.

4.8 Process Monitoring Process Performance SECTION NA

NA for Suppliers who do not have Customers who require process


monitoring. If only cutting fluid flow or pressure monitoring is performed
this section is NA.

Is automated process monitoring in use per the Customer’s YES NO


requirements?

If a monitored parameter exceeds the approved range (e.g. "Process YES NO


Alarms") is there objective evidence that the event was reported,
documented, and evaluated per Supplier and any Customer
requirements? If no such events have occurred, is the operator aware
of the proper response to process alarms?

If a process alarm is the result of a machine or system malfunction, is YES NO NA


there objective evidence that maintenance and requalification were
performed before resuming production?

CAG: NA applies if no such events have occurred ever. The auditor is


to also look at historical events not just on the current job audit. The
auditor is also to check awareness of the procedures to address issue.

Are monitor thresholds determined for each machine, machined YES NO


feature, cutting tool, and/or process condition?

CAG: Note that monitoring requirements may differ between different


cutting tools.

Do actual process monitor alarm limits match the approved values? YES NO

CAG: Verify that the limits programmed into the monitoring system
match the approved values.

4.9 Cutting Tool Usage

Cutting Tool Adequacy

Do cutting tools and abrasives in use at the workstation match the YES NO
approved process and Work Instructions?

Do the tools and abrasives in use meet the Customer requirements? YES NO NA
PRI AC7126/1 Revision B - 13 -

CAG: Examples of Customer requirements include prohibiting the use


of certain tool materials or tool types for particular operations or work
materials. If the tooling has been approved by the Customer, for
example in a signed technical plan, it shall be assumed that all
requirements have been met.
NA applies if the Customer has no restrictions or requirements.

Is each cutting tool/tool Supplier pairing in use approved by the YES NO NA


Customer?

CAG: NA is allowed if the Customer does not require tool/tool Supplier


pairing Customer approval.

Are there controls in place to prevent mixing of approved and YES NO


unapproved cutting tools and abrasives at the workstation?

Does the Supplier’s internal system assure that correct cutting tools YES NO
and abrasives are issued to the workstation?

Does the operator or person performing tool set up verify that the YES NO
cutting tools and abrasives match the work instructions/approved
process?

Are cutting tools handled in a manner to prevent potential damage to YES NO


either the cutting tools or the part being machined?

Are cutting tool markings or package labeling (if packaged until use) YES NO
sufficient to assure that the cutting tool can be uniquely identified and
verified against process documents, the Work Instructions, or the
Customer approved process?

Cutting Tool Change and Tracking

Does the method to determine tool change intervals meet Customer or YES NO
Supplier requirements?

CAG: Criteria to determine intervals may include tool wear


measurement, sampling frequency, documentation, etc.

Do actual cutting tool and abrasive change intervals not exceed the YES NO
approved limits?

CAG: Verify that tools are changed at or before the approved tool
change point or wear limit. If the approved tool change exceeds one
part/feature, there must be a written or electronic (for example within
CNC code) system for tracking tool usage.

Is the operator following the procedure to assure that worn cutting tools YES NO
and abrasives are not inadvertently re-used?

CAG: Verify that there is segregation of tools that have reached the
wear criteria or cutting tool change point consistent with local
procedures.
PRI AC7126/1 Revision B - 14 -

Are finish cuts made with a new cutting tool or cutting edge where YES NO NA
required by the Customer?

CAG: NA applies if the Customer does not require a fresh cutting edge
to be used for finish cuts.

4.10 Hole Finishing

Do burr removal processes meet the Customer requirements? YES NO NA

CAG: Edge break is a controlled operation to produce a specific


geometry per the drawing while burr removal does not have a specific
geometry. “Incidental” burr removal is an area prone to being not
documented.
NA is only allowed if edge break/transition zone or burr removal is not
performed or there are no Customer requirements on
edgebreak/transition zone.

Do hand finishing processes meet the Customer requirements? YES NO NA

CAG: Evaluate hand finishing operations on the audited features


whether they are performed in the same or a subsequent operation.
NA is only allowed if hand finishing is not done or there are no
Customer requirements.

4.11 Hole Inspection

Are inspections performed in accordance with Customer requirements? YES NO NA

CAG: Inspection requirements apply as-machined, prior to subsequent


operations such as peening or painting. This question applies to both
inspections conducted at the machining work station and for final
inspection as applicable.
NA when there is no Customer requirement.

Are Customer stock removal requirements verified? YES NO NA

CAG: e.g. (1) a minimum amount of stock that must be removed by


machining operations; (2) maximum depth of cut.
NA applies if the Customer has no stock removal requirements.

4.12 Identification and Traceability

Is traceability of part(s) maintained according to the Supplier's YES NO


documented procedure?
PRI AC7126/1 Revision B - 15 -

5. JOB AUDIT

NOTE: Fill out as much information as applies. Put not applicable if the
data does not exist. Do not include any information marked (EC) if the
part is export controlled and note it as such. Customer/Subscriber,
Order #, Lot #, and Part number are required.

5.1 Customer Requirements

Job Details

Select the Job’s status:

Completed In Process

Date job was completed if a historical job. _______________

Record the Method audited (from the following):


Holemaking
Holemaking with Process Monitoring
Abrasive Flow Post Finish ________________
Jig Grinding Post Finish
Hone Post Finish

Select whether the Supplier indicated that the part audited was Export
Controlled (ITAR/EAR):

Yes, Export Controlled

Did not indicate Export Controlled

Informational: If the job audit does not cover the “Holemaking with
Process Monitoring” Method, please check to indicate if the equipment
used for the job audit was capable of process monitoring and if it was in
use during the job audit.

If it is in use but not in the scope, the questions on Process Monitoring


do not need to be answered

Complete the following information.

Job Audit Properties

Customer _______________

Subscriber _______________

Unique work Order # or Lot # _______________

Quantity _______________
PRI AC7126/1 Revision B - 16 -

Serial Number of audited part(s) _______________

List the details of the processes and equipment audited _______________

Job Identification

Drawing #/Part Number/Rev. _______________

Purchase Order Number/Rev. _______________

Operation Sequence Number _______________

Class (if applicable) _______________

Specification/Operator/Requirements

Specification/Rev. _______________

Operator Identification _______________

List source of holemaking requirements (Purchase Order, drawing,


fixed/frozen process documentation, internal specification, etc.) ________________

Flow Down

Have quality and technical requirements been flowed down? YES NO

CAG (Compliance Assessment Guidance): Review the Purchase


Order, specification, any other Customer quality/technical requirements
documents and verify that the flow down is correct on all paperwork
(routers, Work Instructions, etc.) through the process. This question
also includes any Purchase Order amendments.

5.2 Process Approvals SECTION NA

NA applies if process approvals are not required by the Customer.

Do the process approval document (technical plan, manufacturing plan, YES NO


data sheet, etc.) contain all of the information per Customer
requirements?

Is there objective evidence of Customer approval for the holemaking YES NO


process(es) being used?

Are all features controlled by Customer engineering requirements YES NO


accounted for in the process approval document?
PRI AC7126/1 Revision B - 17 -

CAG: Verify that all features controlled by Customer requirements have


been submitted for approval i.e. that nothing on the drawing/PO/etc.
was omitted.

Are all operations performed on the controlled features accounted for YES NO
in the process approval document(s)?

CAG: Verify that all operations used by the Supplier to produce


controlled features have been documented/ approved. Give special
consideration to operations not performed as part of machining. For
example, manual deburr, handbench, and separate edgebreak
operations.

5.3 Document Control

Is the process being performed per the current revision of applicable YES NO
requirements?

CAG: This question applies to the approval document for example, a


technical plan or FMP/PX 6041-20. The current revision is defined by
the appropriate flow down documents and may include drawings,
Customer specifications/requirements and/or industry specifications.

Are the Work Instructions at the workstation the current same revision YES NO
and do they match the approved process, and does that planning have
all changes properly incorporated?

CAG: The process described in workstation documentation must match


the Customer approved document. Planning shall be current and have
all changes properly incorporated. Temporary changes to workstation
documentation must be properly approved.

Are changes to the process proposed by the Supplier approved by the YES NO NA
Customer and design authority if required prior to incorporating the
change when required?

CAG: NA applies if no changes have been made or if approval for


specific changes has been delegated to the Supplier by the Customer.

Work Instruction General

Are Work Instructions detailing each operation available at each work YES NO
station and do they show evidence of approval, revision level and date?

CAG: The work instructions themselves may not be approved by the


Customer but must be traceable back to the Customer approved
document.

Are the Work Instructions being reviewed before starting the machining YES NO
process and is the operation performed per the Work Instruction?

Are all process steps that are performed included in the Work YES NO
Instructions?
PRI AC7126/1 Revision B - 18 -

Do the Work Instructions indicate that the operation is frozen to the YES NO
extent required by the Customer?

Do the Work Instructions include all of the information required by the YES NO NA
Customer’s specification, including all required documents?

CAG: NA applies if the Customer has no requirements controlling the


content of the work instructions.

Work Instruction Adequacy

Do Work Instructions identify specific features (or the entire operation) YES NO
to which the Customer requirements apply?

Are all of the controlled features detailed on the Customer’s drawing or YES NO
other Customer flowdown accounted for?

CAG: Verify that all controlled features defined by Customer


requirements have been flowed down and that no controlled features
on the drawing/PO/etc. were omitted.

Do Work Instructions direct that approved process parameters may not YES NO
be overridden (or are locked-out)?

CAG: If the process in question has been approved by the Customer at


one value or range, it must be run at that value or range even if the
Customer’s specification allows a wider range.

Do Work Instructions describe all controlled cutting tools and abrasives YES NO
such that the operator can verify they match the approved process?

CAG: This requirement may be met by a physical description of all


controlled features (including geometry, material, and coating, if any) or
by reference to a drawing, catalogue, crib or other number/code that
uniquely describes the tool.

Do Work Instructions include change intervals or wear criteria for each YES NO
controlled cutting tool or abrasive?

Does the Work Instruction establish a manufacturing YES NO


sequence/chronological order?

Are Customer stock removal requirements documented in the Work YES NO NA


Instruction and performed?

CAG: The requirement for stock removal need not be explicitly stated in
the work instruction as long as the process described achieved the
required material removal. For holemaking, stock removal refers to
radial stock removed between roughing and finish machining. NA
applies if stock removal requirements are not specified by the
Customer.
PRI AC7126/1 Revision B - 19 -

Do Work Instructions indicate the cutting fluid flow rate and/or pressure YES NO NA
if required by the Customer?

CAG: NA applies if flow rate and/or pressure requirements are not


specified by the Customer.

Is there evidence that the tool change point or wear criteria for each YES NO NA
controlled cutting tool or abrasive has been approved by the Customer
during substantiation, if required?

CAG: NA applies if approval is not required by the Customer.

Work Instruction Holemaking Details

For each individual process in making a given hole:

Do the Work Instructions describe the layout and positioning of coolant YES NO NA
delivery nozzle(s) so that it can be set-up repeatedly for each cutting
tool and machining stage?

CAG: The operator needs to be furnished with enough information so


that if the coolant delivery system is disturbed that it can be re-set with
sufficient accuracy to assure that the machining process is not affected.
Boilerplate for similar operations is acceptable. NA is allowed if coolant
is not used. This does not apply to Abrasive Flow and it may not apply
to Jig Grind.

Do the Work Instructions specify the machines approved for use and is YES NO
this consistent with Customer requirements?

CAG: Machine may be identified by make, model and manufacturer


serial number or Supplier local reference number. The intent is that the
Work Instructions clearly indicate which machine(s) is to be used. Refer
to the Customer requirements to determine if work instructions may
apply to multiple machines.

Do Work Instructions (may refer to a revision controlled CNC program) YES NO


list values or ranges for all parameters required to run the process?

Do the Work Instructions detail how to set up cutting tools? YES NO

CAG: If the Supplier has specific Customer requirements, they need to


be in the work instructions. If there are no specific requirements, then
there must be information to allow repeatable set-up of the tooling. The
instructions should be adequate to identify collets, tool holders, etc.,
and their assembly.

Do the Work Instructions include all work holding devices and fixtures YES NO NA
where required by the Customer?

CAG: NA applies if there are no Customer requirements.


PRI AC7126/1 Revision B - 20 -

For hand bench operations on controlled features, do Work Instructions YES NO NA


describe the devices (e.g. air motor), cutting tools and abrasives
approved for processing the features?

CAG: NA applies if there are no hand bench operations performed on


controlled features.

Other Documentation

Is the shop traveler (including equivalent paper or electronic record) YES NO


used to reflect sequence of operations, inspection points, identification
of the individual(s) performing the work and date properly completed?

CAG: Properly means that the paperwork is filled out or acknowledged


electronically as it is supposed to be as required either by the Customer
or by the Supplier’s own rules.

Work Instructions for Process Monitoring SECTION NA

NA If the scope does not include holemaking with process monitoring,


the section is NA.

Do Work Instructions for process monitoring communicate the process YES NO


limits/alarm level(s)?

Are alarm limits (e.g. power, torque, force, flow, etc.) developed YES NO
consistent with Customer requirements?

Have the process limits/alarm level(s) been approved per the Customer YES NO
requirements?

Do the Work Instructions state how to arm the process monitoring YES NO
system and how the operator is to react to an alarm condition?

Is there evidence that alarm events are properly managed per YES NO NA
Customer requirements?

CAG: NA applies if no events have occurred.

5.4 Personnel Qualification

Is there evidence that the personnel received the required training YES NO
before performing controlled operations?

CAG: Some Customer training requirements apply to personnel other


than operators, e.g. process engineers, inspectors, procurement
personnel, tool control personnel, quality engineers, maintenance, etc.
Some Customers have specific requirements regarding training
content, see specific Customer requirements.
PRI AC7126/1 Revision B - 21 -

Is the training for each person involved in the process current per the YES NO
required interval?

CAG: this applies to Customer and/or Supplier required training.

5.5 Equipment

Equipment Adequacy

Is the process running on an approved machine? YES NO NA

CAG: NA applies if the Customer does not require the process to be


run on an approved machine.

Does the machine have the capability to interrupt the machining YES NO NA
operation when a process parameter exceeds a defined range if this
capability is required by the Customer?

CAG: Specific requirements for machine response exist within


Customer specifications. Examples include coolant flow/pressure,
force, power, speed, etc.
NA applies if this is not required by the Customer.

For processes that require cutting fluid flow or pressure sensing, is YES NO NA
there a separate sensor for the through-spindle cutting fluid branch
(where used)?

CAG: NA applies if coolant sensing is not required, through-spindle


coolant is not used, or is used exclusively (flood lines disabled).

Are all gages and process monitoring equipment identified as to their YES NO
calibration status and current as per local procedure?

For process monitoring, does the time threshold of the process YES NO NA
monitoring system meet Customer requirements?

CAG: “Time threshold” refers to the length of time that a parameter has
to stay above a threshold in order for the system to consider it an alarm
and take action.
NA applies if the Customer has no requirements for time threshold.

Equipment Qualification

Are all periodic machine and monitoring system qualifications current? YES NO NA

CAG: Customer requirements may include visible qualification status


on the machine, re-qualification intervals, etc.
NA if there are no functions requiring periodic qualification per
Customer requirements.
PRI AC7126/1 Revision B - 22 -

Equipment Maintenance

Has the preventive maintenance program been completed as per YES NO


schedule and are records available to verify completion?

5.6 Cutting Fluid SECTION NA

Section is NA only if the operation is approved to be run without cutting


fluid.

Does the cutting fluid in use match the documented cutting fluid YES NO
including approval by the Customer if approval is required?

Does the cutting fluid delivery method, match the documented process YES NO
including approval by the Customer if approval is required?

CAG: Customer requirements may include flow rate and/or pressure;


when pressure is specified it is measured with static pressure.

Has the Supplier performed cutting fluid maintenance per their YES NO NA
documented procedure?

Is there a system in place to signal the operator of a significant YES NO NA


interruption in the cutting fluid flow during the machining operation per
Customer requirements?

CAG: An interruption may be partial reduction of flow or pressure in


addition to complete cessation, reference Customer or internal
requirements.
NA applies if there are no Customer requirements on the amount of
fluid flow.

Is there an automated system capable of interrupting the process in YES NO NA


case of loss of cutting fluid flow or pressure if required by the
Customer?

CAG: NA applies if there are no Customer requirements.

5.7 Process Performance

Is the correct version of the NC program in use? YES NO NA

CAG: NA applies if the process being audited is not NC program


controlled.

Do the parameters in use match the NApproved values or ranges? YES NO

CAG: Only parameters such as cutting speed, feed rate, tool change
points, need be verified. Dimensional commands are not to be verified.
If the process is CNC, verify values in the NC program.
PRI AC7126/1 Revision B - 23 -

Are parameters in use within Customer requirements, if applicable? YES NO NA

CAG: NA applies if the Customer does not have any requirements that
limit parameters. The auditor only needs to verify parameters that have
Customer requirements.

Is the use of Speed and Feed override controls consistent with the YES NO NA
Customer requirements?

CAG: NA applies if the Customer does not have any requirements that
pertain to the use of override controls.

Is all shop-level documentation properly completed? YES NO

CAG: shop-level documentation may include routers, inspection


reports, etc.

Is there evidence that local procedures for handling Special Cause YES NO
Events are known to the operator?

CAG: Verbal verification from the operator(s) that is in agreement with


the procedures is acceptable.

Is there objective evidence that any special cause event was reported, YES NO NA
documented, and evaluated per Supplier and any Customer
requirements?

CAG: NA applies if no events have occurred.

Does the actual process match the approved process? YES NO

CAG: The approved process includes frozen/fixed process and any


documented Customer allowed process changes. The scope of this
question can include process steps or process sequence.

5.8 Process Monitoring Process Performance SECTION NA

NA for Suppliers who do not have Customers who require process


monitoring. If only cutting fluid flow or pressure monitoring is performed
this section is NA.

Is automated process monitoring in use per the Customer’s YES NO


requirements?

If a monitored parameter exceeds the approved range (e.g. "Process YES NO


Alarms") is there objective evidence that the event was reported,
documented, and evaluated per Supplier and any Customer
requirements? If no such events have occurred, is the operator aware
of the proper response to process alarms?
PRI AC7126/1 Revision B - 24 -

If a process alarm is the result of a machine or system malfunction, is YES NO NA


there objective evidence that maintenance and requalification were
performed before resuming production?

CAG: NA applies if no such events have occurred ever. The auditor is


to also look at historical events not just on the current job audit. The
auditor is also to check awareness of the procedures to address issue.

Are monitor thresholds determined for each machine, machined YES NO


feature, cutting tool, and/or process condition?

CAG: Note that monitoring requirements may differ between different


cutting tools.

Do actual process monitor alarm limits match the approved values? YES NO

CAG: Verify that the limits programmed into the monitoring system
match the approved values.

5.9 Cutting Tool Usage

Cutting Tool Adequacy

Do cutting tools and abrasives in use at the workstation match the YES NO
approved process and Work Instructions?

Do the tools and abrasives in use meet the Customer requirements? YES NO NA

CAG: Examples of Customer requirements include prohibiting the use


of certain tool materials or tool types for particular operations or work
materials. If the tooling has been approved by the Customer for
example in a signed technical plan, it shall be assumed that all
requirements have been met.
NA applies if the Customer has no restrictions or requirements.

Is each cutting tool/tool Supplier pairing in use approved by the YES NO NA


Customer?

CAG: NA is allowed if the Customer does not require tool/tool Supplier


pairing Customer approval.

Are there controls in place to prevent mixing of approved and YES NO


unapproved cutting tools and abrasives at the workstation?

Does the Supplier’s internal system assure that correct cutting tools YES NO
and abrasives are issued to the workstation?

Does the operator or person performing tool set up verify that the YES NO
cutting tools and abrasives match the work instructions/approved
process?

Are cutting tools handled in a manner to prevent potential damage to YES NO


either the cutting tools or the part being machined?
PRI AC7126/1 Revision B - 25 -

Are cutting tool markings or package labeling (if packaged until use) YES NO
sufficient to assure that the cutting tool can be uniquely identified and
verified against process documents, the Work Instructions, or the
Customer approved process?

Cutting Toll Change and Tracking

Does the method to determine tool change intervals meet Customer or YES NO
Supplier requirements?

CAG: Criteria to determine intervals may include tool wear


measurement, sampling frequency, documentation, etc.

Do actual cutting tool and abrasive change intervals not exceed the YES NO
approved limits?

CAG: Verify that tools are changed at or before the approved tool
change point or wear limit. If the approved tool change exceeds one
part/feature, there must be a written or electronic (for example within
CNC code) system for tracking tool usage.

Is the operator following the procedure to assure that worn cutting tools YES NO
and abrasives are not inadvertently re-used?

CAG: Verify that there is segregation of tools that have reached the
wear criteria or cutting tool change point consistent with local
procedures.

Are finish cuts made with a new cutting tool or cutting edge where YES NO NA
required by the Customer?

CAG: NA applies if the Customer does not require a fresh cutting edge
to be used for finish cuts.

5.10 Hole Finishing

Do burr removal processes meet the Customer requirements? YES NO NA

CAG: Edge break is a controlled operation to produce a specific


geometry per the drawing while burr removal does not have a specific
geometry. “Incidental” burr removal is an area prone to being not
documented.
NA is only allowed if edge break/transition zone or burr removal is not
performed or there are no Customer requirements on
edgebreak/transition zone.

Do hand finishing processes meet the Customer requirements? YES NO NA


PRI AC7126/1 Revision B - 26 -

CAG: Evaluate hand finishing operations on the audited features


whether they are performed in the same or a subsequent operation.
NA is only allowed if hand finishing is not done or there are no
Customer requirements.

5.11 Hole Inspection

Are inspections performed in accordance with Customer requirements? YES NO NA

CAG: Inspection requirements apply as-machined, prior to subsequent


operations such as peening or painting. This question applies to both
inspections conducted at the machining work station and for final
inspection as applicable.
NA when there is no Customer requirement.

Are Customer stock removal requirements verified? YES NO NA

CAG: e.g. (1) a minimum amount of stock that must be removed by


machining operations; (2) maximum depth of cut.
NA applies if the Customer has no stock removal requirements.

5.12 Identification and Traceability

Is traceability of part(s) maintained according to the Supplier's YES NO


documented procedure?