Process Name - Weld Audit- 14058

Version: Initial Release Issue Date: June 30, 2009

Auditor: Date: Score

Supplier: Location: 0%
Duns: Part Name: RED

A. Weld System Audit Questions AUDIT WORKSHEET

EVIDENCE/ G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

What is the Welding transfer being used (Pulse, Short Arc, Enter required evidence NR NR ###
1 Spray, etc) description WPS should have process listed
NR NR ###
2 What weld wire classfication and wire size is being used? WPS should have info listed
How is the welding being controlled ? (robot speed, feed- NR NR ###
3 rate of wire, amperage, etc.) Yes or No

Are all components of your weld system (power sources,

robot, wire-feeder, gas-flow etc.) calibrated? If yes, how is NR NR ###
4 it done? Frequency? Yes or No

Is there a Preventive Maintenance (PM) plan on the Robots

and Welding System (Power Source, Feeder, Welding Torch, NR NR ###
5 Reamer Unit, etc) and is it followed? Review all Documentation
NR NR ###
6 Are there spare parts identified and currently in supply? Suggested for long lead time items only

Verify components and feed drive roll tensioner setting . Feed and
measure a timed wire segment, or read calibrated independent wire NR NR ###
7 Check weld wire feed delivery system driven tachometer
Total

B. Quality System Audit Questions AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

Are sample size and check frequency for each weld Enter required evidence The approved weld verification frequencies are based on weld NR NR ###
1 operations reasonable? description counts, locations and risk
Standard cross-sectioning procedures should be posted in weld lab NR NR ###
2 Is there a detailed cross-sectioning procedure available? and submitted in plan
Is there evidence that the cross-sectioning procedure is Samples or digital images should be available for review during the NR NR ###
3 followed? audit
Are the measuring devices for the cross-sectioning Calibration records for all measurement devices should be tracked NR NR ###
4 calibrated? and available
Are proper operator instructions available for each weld NR NR ###
5 operation? This should be followed as part of the PPAP value stream procedure
Are Standardized Work instructions detailed to run the weld NR NR ###
6 cell properly? This should be followed as part of the PPAP value stream procedure

Does the supplier include weld repair in the PFD, PFMEA, Weld repair procedures are clearly identified within the GMAW NR NR ###
7 Control Plan, Work Instruction & is it acceptable? 14058 specification and should be posted at the cell
Are the operators properly trained? Do they understand the NR NR ###
8 instructions? Refer to the QSB standard for operator training matrix
Are Master Parts available at the line side for operator to NR NR ###
9 review Supplier to conduct a "Layered Audit" within the department
Does the supplier have sufficient checks in place at GP 12 for GP 12 area should be specific for weld samples, pictorial, NR NR ###
10 weld processes? specification and instructions
Total

C. Shielding Gas Audit Questions AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

What is the Shielding Gas mixture rate (eg: 90/10 % of Enter required evidence NR NR ###
1 Ar/Co2) description Review documentation
2 How is your shielding gas mixed? In house via gas mixer or bottled gas from local Supply house NR NR ###

How is the pressure of the shielding gas monitored? Alarm NR NR ###

3 when pressure drops below a certain threshold? Review documentation
4 Who is in control of the shielding gas mixer? Is it a Maint Tech, a Weld Tech or a Welding Eng or other Eng NR NR ###
Are there checks to validate shielding gas settings and if so NR NR ###
5 when and by whom? Review documentation
3 G Total

D. Error- Proofing Audit Questions AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

Verify welding torch and mounting brackets are tight and in Enter required evidence NR NR ###
1 correct position. description Validated via a TCP check program was / created and validated
How are the robots TCP (Tool Center Point) maintained and NR NR ###
2 is there a PM for the robots TCP Min once a Month

If a robotic crash occurs, how is the recovery handled? Is a NR NR ###

3 TCP verification done prior to welding next part? Review documentation
What is the frequency of change of the weld tip? Is it being NR NR ###
4 done per the prescribed frequency? Review documentation
Total

E. Safety Welds and Equipment AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

Where the Weld Process Control Plan calls for SPC, is the Enter required evidence NR NR ###
1 data properly recorded? description GM PPAP requirement if shown in "Statement of Requirements"

Are the Upper Control Limits (UCL) or Lower Control Limits

(LCL) current relative to latest design/material thickness Refer to AIAG statistical manual, revision required base on tooling NR NR ###
2 change? Does the data make sense? improvements
Are out of control points noted with the corrective action PPAP requirement specifies corrections required for FULL NR NR ###
3 taken? APPROVAL
Mechanical or electrical devices should be tested prior to starting NR NR ###
4 Are all safety devices operating properly and checked daily? the production weld cell
5 Are documents available for review? Layered Audit Process NR NR ###
Total

F. Summary Questions AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

Are Global Weld Specifications for their weld processes Enter required evidence NR NR
1 being followed? description Generally discussed in the PDT or early Gate Reviews
 Does the supplier know where to get the latest information NR NR ###
2 on GM Supply Power? Manufacturing section or search Controls, Robotics, Welding
Does the supplier have the latest GM weld PFMEA for GM Weld PFMEA May 07 is available from your SQE, located in the NR NR ###
3 thought starters? share drive
Are the suppliers using the "DDW READ ACROSS" format for This strategy should be used for all GM applications, shown in GM NR NR ###
4 each assembly? 1927
Total

SCORE

Rating:
Green ≥ 90% / Yellow 70-89% / Red ≤ 69%

Sections Percent of compliance Results score

A. Weld System Audit Questions 0% RED ###
B. Quality System Audit Questions 0% RED ###
C. Shielding Gas Audit Questions 0% RED ###
D. Error- Proofing Audit Questions 0% RED ###
E. Safety Welds and Equipment 0% RED ###
F. Summary Questions 0% RED ###

If any of the single sections is rated RED, overal audit result is RED with 0% score

Summary score 0% RED Pts Element Scoring

Requirements not met, needs immediate correction
0 SQE to assure actions are in place prior to leaving the facility,
including CS1/2 implementation if necessary
Requirements not met, process acceptable with additional controls in
1 place

2 Requirements met, process has improvement potential

3 Requirements fully met, best practice process in place

NA Not Applicable (does not impact audit score)

Supplier Representative Name with Signature

GM Representative Name with Signature NR Not Rated (impacts audit score)
Process Performance SUPPLIER ACTION PLAN REPORT Rev. 7 1/7/02

Supplier Start Date: SQE

Location Rev. Date: SQE Phone:
Duns Grad Date: Manager:
Commodity Program: Group:
Prepared by: Creativity Team:

G Green - Task Completed on Time

Y Yellow - Task May Be Late
R Red - Task is Late
W White - Task Re-Timed, No Status
B Blue - Task Status is Incorrect / Not Updated
On Track (Bold Box/No Color)
STATUS
Most
Oldest Recent

AUDIT DATE TARGET ACTUAL LAST

ITEM Priority ACTION ITEM ACTION LEADER 1 2 3 4 5 6 COUNTER MEASURES
SECTION OPENED CLOSE DATE CLOSE DATE UPDATE

1
2
3
4
5
6
7
8
9
10

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Process Performance SUPPLIER ACTION PLAN REPORT Rev. 7 1/7/02

C5: Person at supplier that prepared the form for the GM SQE. (If applicable)

C16: 1- Normal priority

2- High priority

3- Highest priority
D16: ACTION ITEM: The item that requires action to improve the process or quality of the product being produced.

E3: Graduation Date:

This Date Will Be Determined By GM SQ Directors
E4: For PDC SQE Only:
Identify which program your supplier is in "IQ' or "SQA".

E16: ACTION LEADER: The person that leads the team to make the improvements. This should be the suppliers person but may be a GM Management person.
F16: START DATE: The date the action item was identified and listed in the action item column
G16: TARGET CLOSE DATE: The date the supplier will complete the action item.

This date may change. If the date changes, you are required to entry the correct color code in the pass status and present status columns.
A comment on why the change to be entered in the comment field
H16: ACTUALCLOSE DATE: The date the action item was closed TO INCLUDE VALIDATION.

The SQE should validate the action item as being closed and RESOLVED.
I16: LAST UPDATE: The date the SQE reviewed the action item.
J13: PAST STATUS: The cell is filled in when the status changes. Oldest status to the left
If status is WHITE put a "W" in the cell. Do not leave blank.
Copy the cell for the correct color.

COLOR CODE:
GREEN: Task Completed on Time
YELLOW: Action item is in trouble and may affect target date.
RED: Action item has missed target date.
WHITE: Task Re-Timed, No Status
BLUE: Task Status is incorrect / Not Updated
P16: COUNTER MEASURES:

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Audit form developed by:
Name Department Region Phone Mail
Maryland Berry Dept

Changes Log:
Date Version Description
6/30/2009 Initial Releae Initial audit release