Process Name - Exhaust Pipe Bending Process

Version: 1 Issue Date: June 11, 2013

Auditor: Date: Score

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

A. Material AUDIT WORKSHEET

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

Check the defined design and Mill sheet for pipe material (Chemical
1 Does the pipe material satisfy to the GM spec? component and mechanical characteristic) NR NR ###
- Check for external Lab report verification.
Are parts satisfied to the corrosion resistance and thermal
2 resistance?
Check whether the parts are used correct type and purpose. NR NR ###
Does the part is satisfied corrosion resistance of GM Verify the corrosion resistance regularly test result. (Salt spray test
3 requirement? report)
NR NR ###
Total

B. Pipe Welding AUDIT WORKSHEET

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

Does pipe welding parameter condition control managed Check the welding process whether it is follow to the work instruction
1 procedure when plasma or laser welding? (current, voltage, velocity, time etc)
NR NR ###
2 Does control plan include welding parameter? Check control plan is prepared based on PFMEA or not. NR NR ###
Check changing procedure of set up the welding parameter and the
3 What is the welding parameter changing procedure?
control method
NR NR ###
4 Is pipe welding machine checked regularly? Check the machine check sheet at the begging NR NR ###
5 What is the pipe welding rework process and action plan? Check the pipe welding rework process and action plan NR NR ###
6 What is the preventive maintenance plan? Check the preventive maintenance plan. NR NR ###
Are parts for welding machine verified and set up the life
7 cycle?
Check the spare part list and life cycle list NR NR ###
Check the welding standard for joint spot. (crack, porosity, harmful
8 What is welding standard for OK part and NG part?
defect etc..)
NR NR ###
Check the welding test process and check it that is followed GM
9 What is the detail test procedure after welding process?
SPEC or not. (Destructive and Nondestructive inspection)
NR NR ###
Do welding testing machines are set up the maintenance
10 cycle and managed the history?
Check the checking cycle plan and performance. NR NR ###
Check the Inspection standard, and Check whether operator was
11 Is the pipe managed the roundness and the dim's?
follow it
NR NR ###
Total

C. Bending AUDIT WORKSHEET

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

Does each bending line display the work instruction and set Check the work instruction, and whether operator follow it.
1 up the key point? (Work method, Grease specification, oil kinds, etc)
NR NR ###

Does the pipe contraction satisfy to the GM spec? Should be include to working standard and follow GM specification.
2 What is the checking method? Check the evidence. NR NR ###
(Check contraction ratio 10%)

Bending machine has a leakage at oil system? Check loose Check evidence of machine maintenance sheet (lubricating oil,
3 mounting. pressure, wear of tool, etc)
NR NR ###

4 Is there evidence of maintenance plan and result? Check plan of maintenance plan and result for wiper, roller, slider NR NR ###

Does supplier inspect component parts for crack, burrs, Is there a standard procedure and control method for pipe expansion
5 sharp edges after expansion process? process? NR NR ###

Operators need to understand characteristic of product and

6 working method. Check training record, skill matrix and test operator's understanding. NR NR ###
Does operator is trained to do set up change, approval
Does the supplier have known parts that fail and no fail? Review the master parts to see if they indeed have both bad and
7 And checked regularly? good parts.
NR NR ###

Is Check fixture is available? And check fixture is maintain as

8 planed?
Should have record for gage maintenance and inspection result. NR NR ###

Operator is understanding handling methods for check Should displayed inspection standard at working area.
9 fixture and inspection method follow inspection standard? Check result of inspection and test operator's understanding. NR NR ###

Review conversions from XYZ to bend data or LRA (Length, Rotation

Ensure Bend dimension, XYZ and IJK "slice" (Using and Angle) for bending machine. Are they correct and statistically
theoretical centerlines of bends of pipe) are correct to math capable to the desired CPK values? CNC benders use Length,
10 data. Ensure volumetric movement of pipe will not impinge, Rotation, Bend Radius, so it's important to review ranges of setting in
NR NR ###
mis-build or block interfacing components. machine, review trace history on adjustments to verify bender and
piping are stable.
Does first piece & last piece approval followed & all the
critical charatecteristics like bend dimensions, positional
11 tolerances, wrinkles, crack on seam etc. are parts of
Check first piece & last piece approval report. NR NR ###
inspection report
Is the positional tolerances of bend pipes is sufficiently less
12 than final assy drawing positional tolerances?
Check for stage drawing's spec & checking gauge CMM report. NR NR ###
Check operator work instruction, as bending centre line & pipe
Does the welding line of pipe is 90° with respect to bending
13 centre line during the bending operation?
welding centre line is in same line may cause crack at welding & NR NR ###
minor leakage.
IF Bending machine is CNC Check operator work instruction & back up training documents,
- How the operator select the programe & modify the regarding programe selection, modification & correction a operator
14 programe if some bending dimension is out of spec.? can do in any direction (Rotational direction, linear direction & angular
NR NR ###
- Upto what limit operator can change the programme? direction)
Is tool life monitored for for wiper, roller, slider, collet etc & is Check tool life tracking sheet, as wiper, roller, slider may be common
15 linked with production made.? for other exhaust pipes of GM parts / other customers.
NR NR ###
Total

D. Forming & Cutting AUDIT WORKSHEET

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

Does each Forming & Cutting line display the work

1 instruction and set up the key point?
Check the work instruction, and whether operator follow it NR NR ###
Is maintenance period of forming machine and checked Does the supplier have a replacement period and reaction plan if the
2 regularly? part fails?
NR NR ###
Check inspection standard.
3 Is there Inspection standard for after forming and cutting?
Operator should inspect quality of appearance, length, angle.
NR NR ###
Check criteria to do sizing operation, generally it is done when cutting
Does the sizing operation done to compensate ovality of pipe
4 due to bending operation?
is done near bend shape, straignt portion to hold the pipe during NR NR ###
bending is less, etc.
Does sizing operation work instruction showing collet & Verify the collect & mandrell is identified for diffenent combination of
5 Mandrell sizes for different pipes outside diamter & thickness of bended pipe.
NR NR ###

Does deburring is done to remove sharp edges formed

6 during cutting operation & backed up with work instruction
Check the work instruction, and whether operator follow it NR NR ###

Total

E. Safety AUDIT WORKSHEET

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

Does required PPS is identified for operator & displayed on

1 shop floor
Actual observation NR NR ###
 Is bending machine safety area is defined & sensors are Check for Green & Red zones actual check, whether pokayoke is
2 working. working in actual or not.
NR NR ###
- Check while clamping the pipe & operators hand should not be in
3 Is Do's & Don’t's displayed for bedning operation contact with part. NR NR ###
- Operation start is done by hand not by foot
Is Forming & Cutting machines are protected with covers /
4 shields during actual operation.
Witness the actual operation cycle. NR NR ###
Total

F. Critical Spare AUDIT WORKSHEET

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

Is list of critical spares identified & maintained separately for

below operations? Equipment spare parts are carried to ensure continuity of production
1. Bending if there is a breakdown. It is even more critical if the equipment was
1 2. Forming manufactured and imported from overseas. Check inventory for
NR NR ###
3. Cutting spares and what is the longest lead time on the spare parts.
4. Sizing
Total

SCORE

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

Sections Percent of compliance Results score

A. Material 0% RED ###
B. Pipe Welding 0% RED ###
C. Bending 0% RED ###
D. Forming & Cutting 0% RED ###
E. Safety 0% RED ###
F. Critical Spare 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

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569098042.xlsx Printed: 01/07/2022 Page 3 of 4

Audit form developed by:
Name Department Region Phone Mail
Hyunseok Lee; Collaborator : Mangesh Malpure Dept

Changes Log:
Date Version Description
10/14/2010 Initial Release

- 1 modification in SECTION 1 : MATERIAL

6/11/2013 Rev.#1 - 7 modifications in SECTION 3 BENDING
- 3 modifications in SECTION 4 : FORMING & CUTTING
- New section added " SAFETY" carries 4 check points.
- New section added " CRITICAL SPARES" carries 1 check points (common & applicable for all sections)