SPECIFIC PROCESS AUDIT - GMW 14058 GAS/MIG WELDING

Version: Issue Date:

Auditor: Date: Score
Supplier: Location: 0%
Duns: Part Name: RED

A. Weld System Audit AUDIT WORKSHEET

G
EVIDENCE/ DOCUMENT
QUESTION: QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
NUMBER OR OWNER R

What type of weld transfer process being used:

1.1 Pulse, CMT, Short Arc, Spray, Continuous, Stitch, NR NR ###
etc.? WELD PROCESS SHEETS (WPS) should have process
details listed
What type of weld wire classification and wire WPS and PCP should have information listed…PPAP,
1.2 NR NR ###
gauge/size are being used? IMDS requirement (label shown on spool or barrel)
How is the welding being controlled? (ARC time, feed Specify Manual or Robotic PLC system, Brand name,
1.3 rate of wire, voltage amps, travel speed, etc.) NR NR ###
Model or Series number, etc.

Are all components of your weld system (power

1.4 sources, robot, wire-feeder, gas flow, etc.) calibrated NR NR ###
and is it reasonable per Process Control Plan? Review the PPAP document section PCP, Tooling set up,
Maintenance plan
Is there a Preventative Maintenance (PM) plan on
the Robots and Welding System (Power Source,
1.5 Review Maintenance Details as shown as a line item on NR NR ###
Feeder, Welding Torch, Reamer Unit, etc.) and is it
being followed? the PPAP checklist, ask about long lead time purchased
items
Are there spare parts identified correctly and Vending style storage seems to be preferred, Example:
1.6 currently in supply or available immediately? NR NR ###
catalog P.O. style for long lead time items only
What type of controls are in place to check the weld
1.7 wire feed delivery system and notification of wire coil Verify feed control device and rolled wire tensioner
setting, measure a timed wire segment, or read
NR NR ###
change when it is required?
calibrated wire driven tachometer
Total

B. Quality System Audit AUDIT WORKSHEET

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EVIDENCE / DOCUMENT
QUESTION: QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
NUMBER OR OWNER R
Are sample size and check frequencies for each weld The approved weld verification frequencies are based on
2.1 NR NR ###
operation reasonable and followed? weld counts, locations and risk
Is there a detailed cross-sectioning or cut & etch Standard cross-sectioning procedures should be posted
2.2 NR NR ###
procedure available? in weld lab and submitted in plan

Is there evidence that the cross-sectioning procedure Samples or digital images should be available for review
2.3 during the audit. Evidence stored in a Health Chart NR NR ###
is followed?
database

Are the measuring devices such as macroscope for

2.4 Calibration records for all measurement devices should NR NR ###
the cross-sectioning onsite and calibrated?
be tracked and available (15x variable minimum)
Are the proper Operator Instructions available for This should be followed as part of the PPAP value stream
2.5 NR NR ###
each weld operation? PFD diagram
 Are Standardized Work Instructions detailed to run Refer to the BIQS element for Standardized Work
2.6 NR NR ###
the weld cell properly? Practices ask typical questions
Does the Supplier include weld repair steps in the Weld repair procedures are clearly identified within the
2.7 PFD, PFMEA, Control Plan, with Work Instructions? If GMW 14058 specification and should be posted at the NR NR ###
so, are they acceptable? cell
Are the Operators properly trained? Do they
2.8 NR NR ###
understand the Work Instructions and standards? Refer to the BIQS standard for operator training matrix
Are visual master parts available at the line side or Supplier to conduct a "Layered Audit" within the
2.9 nearby for Operators to compare or review? NR NR ###
department
Does the supplier have the effective "Source Source Inspection or Verification Station should be in-line
Inspection" or "Verification Station" in-line as and specific with Master weld samples, Sensory visual
2.10 NR NR ###
described in the CG4352 document for the weld pictorial, GMW specification and proper instructions for
process? inspection and recording any discontinuities.
Total

C. Shielding Gas Audit AUDIT WORKSHEET

G
EVIDENCE / DOCUMENT
QUESTION: QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
NUMBER OR OWNER R
What is the Shielding Gas mixture rate (i.e. 90/10 %
3.1 of AR/Co2)? NR NR ###
Review documentation
3.2 How is your shielding gas mixed? In house via gas mixer or torpedo style bottled gas from NR NR ###
the local supply house
How is the pressure of the shielding gas being
3.3 monitored (alarms, manual gages, sensors)? NR NR ###
Review documentation
Who is in control of the shielding gas mixer and how Request evidence of this calibration..at a minimum it
3.4 NR NR ###
often is it certified? should be annually
Are there checks to validate shielding gas settings
3.5 and if so when and by whom? NR NR ###
Review documentation
Total

D. Error- Prevention Audit AUDIT WORKSHEET

EVIDENCE / DOCUMENT G
QUESTION: QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
NUMBER OR OWNER R
Verify welding torch and mounting brackets are tight Confirm the TCP check program was created and
4.1 NR NR ###
and in correct position? activated into the standard weld process routine
How are the robots Tool Center Point (TCP)
4.2 maintained and is there a Preventative Maintenance Minimum once every shift, set-up, consumable NR NR ###
for the robots? component change or after an unplanned occurrence
If a robotic crash occurs, how is the recovery Review documentation for set up procedures and special
4.3 handled? Is a TCP verification done prior to welding NR NR ###
cause
the
What next part?
is the frequency of change of the weld tip and is
4.4 it reasonable to prevent weld failures? NR NR ###
Review documentation
Total

E. Safety Welds and Equipment AUDIT WORKSHEET

EVIDENCE / DOCUMENT G
QUESTION: QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
NUMBER OR OWNER R
Where the Weld Process Control Plan calls for SPC, GM PPAP requirement if shown in "Statement of
5.1 is the data properly recorded?
NR NR ###
Requirements"
 Are the Upper Control Limits (UCL) or Lower Control
5.2 Limits (LCL) current relative to latest design/material NR NR ###
Refer to AIAG statistical manual, revision required base
thickness change? Does the data make sense?
on tooling improvements
Are "ALL" out of control points noted with the PPAP requirement specifies corrections required for
5.3 corrective action s documented? NR NR ###
FULL APPROVAL
Are all safety devices operating properly and checked
daily? All safety devices should be tested prior to the start up of
5.4 the weld cell. Confirm line item is on the set-up NR NR ###
checksheet
5.5 Are documents available for review? Layered Audit Process NR NR ###
Total

F. Summary AUDIT WORKSHEET

G
EVIDENCE / DOCUMENT
QUESTION: QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
NUMBER OR OWNER R
Are Global Weld Specification for their weld
6.1 NR NR ###
processes being followed? Generally discussed in the PDT or early Gate Reviews
Does the Supplier know where to get the latest These are purchased GMW specification documents for
6.2 information on GM Supply Power? suppliers NR NR ###
Does the Supplier have the latest GM weld PFMEA GM Weld PFMEA May 07 is available from your SQE,
6.3 for thought starters? NR NR ###
located in the share drive
Are the Suppliers using the "DDW READ ACROSS" This strategy should be used for all GM applications,
6.4 format for each assembly? NR NR ###
shown in GM 1927
Total

SCORE
Rating:
Green ≥ 90% / Yellow 70-89% / Red ≤
69%
Sections Percent of compliance Results score
A. Weld System Audit 0% RED ###
B. Quality System Audit 0% RED ###
C. Shielding Gas Audit 0% RED ###
D. Error- Prevention Audit 0% RED ###
E. Safety Welds and Equipment 0% RED ###
F. Summary Questions 0% RED ###
If any of the single sections is rated RED, overall audit result is RED with 0% score Pts Element Scoring

Requirements not met, needs immediate correction

SQE to assure actions are in place prior to leaving
0 the facility,
including CS1/2 implementation if necessary

Requirements not met, process acceptable with

Summary score 0% RED 1 additional controls in place
Requirements met, process has improvement
2 potential

Requirements fully met, best practice process in

3 place
Supplier Representative Name with Signature Representative Name with Signature NA Not Applicable (does not impact audit score)

NR Not Rated (impacts audit score)