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GPSC Supplier Quality Process Control Plan Audit Summary Sheet GM 1927-16
GPSC Supplier Quality Process Control Plan Audit Summary Sheet GM 1927-16
Reason For Audit: Future ✘ Launch Current Partial Other Safety Related Part ? Yes No N/A
Type of Audit: Initial Follow Up Run at Rate (GP9 Attachment B) Product Validation Complete: Yes No N/A
Driver of Audit: APQP Confirmation Mgmt. Request Plant Request Run @ Rate CPIP/Warranty
Top Focus CSL-1 CSL-2 Major Disruption Shutdown/Start Up Audit
Critical Fastener (D02)
Component Check Plan D/PFMEA DD&W Other
Focus of Audit: Part / Assembly Operation / Machine Line /Cell Complete Mfg. System
Quality System - Ongoing Documentation
NR 0 Technical Information Availability GREEN 0 Element is not in place and no evidence of plans to implement
NR 0 Quality System Documentation GREEN 1 Element is not in place but a plan to implement is documented
NR 0 Quality System Implementation Plan GREEN 2 Element is in place but it is not being followed
NR 0 Quality System Implementation by Management GREEN 3 Element in place but not followed at each job or all the time
Approved Approved, but need Documentation Not Approved Follow-Up Audit Date:
In case of deviations use GM 1927-79 Supplier Action Plan Form
7 Existe um PFMEA disponíveis? Current Updated FMEA Verify team members , dates etc. of actual PFMEA. NR G
O NPR esta aceitável de acordo com manual AIAG
PFMEA Changed Log,
( Incluir as caracteristicas de segurança, cotas Verify that ALL high RPN or Critical line items have action plans which include Error
8 Meeting Minutes or Similar Proofing. NR G
críticas e de montagem)?
History
Do RPN numbers reflect latest AIAG edition ? (4th edition March 2006)
PFMEA Changed Log, Evidence of current issues are related back to P.M. Check Sheet.
Existe alguma evidencia das atualizaçoes dos Review P.M. Log for TYPE of Interval.
9 Meeting Minutes or Similar Is it TIME or QUANTITY based (P.M.)? NR G
FMEAS
History Verify that PFMEA is updated as required & matches Control Plan (Review PRR's).
Verify any current failure mode is present on the PFMEA.
Are controls in place to ensure only approved Certification/Test Records Review Incoming Inspection Sheets (if available).
18 Review Hold or Reject area for Incoming Inspection area (component NR G
incoming material released for production? Cumulative Control Data parts/assemblies on the manufacturing floor are approved prior to release)
Gage and Tool Certification Check to make sure gauges are calibrated.
22 Are all gauges calibrated? Verify tools and gages are to the latest engineering change level. NR G
Records
Gage and Tool Certification Check to make sure tools and gauges are certified.
23 Are all tools and gauges certified? Verify tools and gages are to the latest engineering change level. NR G
Records
Is gauge Repeatability and Reproducibility less Check to make sure that gauge R&R is done on a yearly basis for all gauges. If gauge
24 Gage R&R Documentation R&R is between 10 and 30 percent (MSA & PPAP Manual). NR G
than 10%?
25 Do all gauges have proper operator instructions? Gauge Instructions Ensure that Gauge Instructions are attached to the gauge. NR G
Are proper operator instructions available for each Verify operator instructions are firmly attached and visible to operator during gauging
26 Operator Instructions process. NR G
operation? Verify instructions are to the latest engineering change level.
Are boundary samples (BS) available to operators Verify operations are being performed as indicated in work instructions (job time,
32 Operator Instructions handling of non-conforming material etc). NR G
and in use? Verify that supplier has actual boundary samples for review.
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Process Control Plan Audit Worksheet Printed 12/09/2021
Look at actual SPC records and data collection. Are all data boxes filled in?
Are control limits calculated?
Where the Process Control Plan calls for SPC are Process Control Plan Are there trends/patterns present that would indicate a need to recalculate limits?
39 Are the limits actually control limits or are they spec limits? NR G
the data properly recorded? SPC Records Do the control limits exceed the specified tolerances?
Do the limits indicate the process to be incapable and yet the process is allowed to
run?
Are out of control points noted with the corrective Review actual SPC records.
42 SPC Records Every point out if control requires a note outlining corrective action. NR G
action taken? Answer no if any out of control point is not explained.
Are product audits showing acceptable results for Dock and Incoming Audit Documented failed parts per shipment.
43 Dock Audits/Tracking Trends/Discrepant Parts. NR G
Final Product? Sheets, Layered Audits
Does the manufacturing process demonstrate the Review current capability records.
44 Ppk Studies Does the process demonstrate a minimum of 1.67 Ppk / 1,33 Cpk for KPC's (per NR G
required capability or performance? PPAP Manual)?
Does WIP protection at supplier have adequate protection to protect parts from
Does packaging and material handling protect damage until packed and on carrier?
parts from damage? Dock and Incoming Audit Is there evidence that damage observed at assembly center, etc, is present at
45 supplier? NR G
Especially, have adequate protection to protect Sheets
Are there any PRRs related to Package and Handling?
metallic parts from rust? For Material handling for the entire process, are parts protected from damage?
Regularly review SPC data, check to see that there is a system to manage out of
Does leadership ensure that Out of Control SPC Records control conditions that includes action plans with assigned responsibility.
49 Ask someone noted on the action plan to explain their involvement and or NR G
Conditions & nonconformities are managed? Action Plans
responsibility.
Document effectively and timely, check to see that there is a system to manage out of
Are Action Plans (AP) for all nonconformities SPC Records control conditions that includes action plans with assigned responsibility.
50 Ask someone noted on the action plan to explain their involvement and or NR G
followed? Action Plans
responsibility.
From SPC review, check to see that there is a system to manage out of control
Is responsibility for implementation assigned and SPC Records conditions that includes action plans with assigned responsibility.
51 Ask someone noted on the action plan to explain their involvement and or NR G
do people understand their responsibility? Action Plans
responsibility.
Are problems quickly communicated to people who Does an escalation process exist to quickly communicate to the appropriate level
52 Problem Log within the organization and ensure that support and action plans are followed. NR G
can help?
Is there evidence that all concerns are tracked back to the PFMEA to confirm that the
Are all checks to be done under the PCP failure mode has been included?
requirements performed? PFMEA Look for PFMEA change log cross referenced to PRR log, customer complaint log,
55 voice of the process review, warranty data, etc. NR G
Are results properly documented? Process Control Plan
Is there evidence that controls have been added, or controls/RPNs revised based on
Are suitable actions taken in case of deviations? concerns.
Are major process parameters identified with Determine which process parameters satisfy the product specifications with
DOE or other reasonable evidence. These parameters should be included in the PFMEA and PCP.
reasonable evidence [example:DOE (Design of This evidence is recommended as a DOE (Design of Experiment) or Full Factoral
56 experimental date NR G
Experiment) or Full Factoral method etc. ] and method and should be validated with enough sample size. The defined critical
Process Control Plan process parameters should be controlled and password protected in the PLC
controlled with the PCP? (Programmable Logic Controller). Supervisor’s approval would be required to change
the parameters.
Are plans in place to implement all elements of Perform and complete QSB Is there evidence of a QSB Audit? Has the supplier had a QSB Workshop? What is the
57 plan to implement QSB principals and elements? Is there a Master Dot Action plan for NR G
Quality System Basics (QSB)? Audit and action plans all red and yellow QSB elements and PCPA elements?
Supplier Representative Name with Signature Follow-Up Audit Date GM Representative Name with Signature
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