GM 1927 16b Stamping Process Audit

Auditor: Date: Score

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

A. COILS/BLANKS AUDIT WORKSHEET

EVIDENCE/ G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

Incoming material should arrive packaged or protected

Visual Inspection of
Use of acceptable material: Incoming material to incoming material area.
Review supplier process for
1 be properly packaged, clean, free from damage, receipt of incoming material
foreign material and rust/oxidization. and for control of non
conforming material.
as specified in the purchased order. Material shall be
clean, free from damage, foreign material and debris, e.g.
grease, wood slivers, etc. Material must be stored where R
it will be protected from the elements. Measures need to
be taken to prevent exposure to moisture that could lead
to the development of rust/oxidization.

Incoming material should be checked against the

2 Use of correct material grade and thickness
Review released material purchase order and drawing specifications and ensure
specification, material the correct grade and thickness. The supplier should have
certification sheets, and evidence of receiving incoming certification reports.
process of verification. How Supplier shall check thickness, verify R
does supplier record data chemistry/mechanical properties, Zinc coating weight, coil
into their quality operating width. Any material change/substitution must be
system requested and approved by GM engineering, followed
with an EWO or TWO for authorization for production.

Were tailor welded / tailor rolled blanks are used, is GM SQE to verify error Ask supplier to demonstrate error proofing. Re-orientate
3 error proofing in place to assure proper orientation proofing in place and blank to incorrect possitions and verify system stops R
of the TWB throughout the process functional. process.
Were tailor welded blanks are used, is error GM SQE to verify error Ask supplier to demonstrate error proofing. Re-orientate
4 proofing in place to assure material offset from thin proofing in place and blank to incorrect possitions and verify system stops R
to thick is on correct side of part? functional. process.

Review work instructions

and how operator
Confirm with the supplier what the blank size is and
5 Blank dimensions correct for width / length? documents measurements R
and approval to use for ensure correct.
production

Review supplier Parts identified as a severity 10/9 must be free from burrs
Preventative Maintenance
6 Part free of burrs and sharp corners Procedure and inspect
and sharp corners. Burrs on parts with no severity criteria R

parts (Attribute Inspection) must be within 10% of material thickness (industry std).

Total

B.FORM AUDIT WORKSHEET

EVIDENCE / G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
Review of supplier
DFMEA/PFMEA GAP PFMEA severity must match DFMEA severity. High
Supplier to have reviewed the DFMEA and
7 Analysis. Review with supplier severity elements must have appropriate detection R
correlated DFMEA to PFMEA to assure DFMEA/PFMEA means.
alignment

Attribute inspection Verify the supplier is checking hole diameters and

No deformation of pierced holes during the forming process/1st off/in positional tolerance during the stamping operations. The
8 R
operations? process/last off, per PCP. Process Control Plan and the PFMEA should make
Compare to master sample reference to holes.

Prior to production, review After forming; part should be free of wrinkling and folded
Part free of un-acceptable wrinkles and folded over forming diagrams. During over metal. Approved Master sample must be available
9 production run, review parts R
metal. and subject to attribute for comparison. The Process Control Plan and PFMEA
inspection. need to make reference to wrinkling.

Prior to production, review After forming part must be free of splits and edge
forming diagrams. During
cracking. Master sample to be available for comparison.
10 Part free of splits and edge cracking. production run, review parts R
and subject to attribute Review the Process Control Plan and PFMEA and ensure
inspection. controls are in place

Part to exhibit thinning only as predicted in forming

Material thinning to be within acceptable limits and Review forming diagrams.
11 During production run analysis. Have supplier provide cut samples, circle grid R
in areas predicted by formability analysis. review parts. study or sonic check data.

Part may have a minimum stretch requirement to achieve

Part to have adequate stretch per formability / Review forming diagrams.
certain material properties or dent resistance. Have
12 circle grid analysis when required. Ex. Class "A" During production run R
review parts. supplier provide cut samples, circle grid study or sonic
outer panels.
check data.
Total

C. RESTRIKE OPERATION AUDIT WORKSHEET

EVIDENCE / G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
Some parts are coined to ensure form accuracy or to
Review GD&T /DFMEA as
Propper coining to occure where required per flatten burrs. These areas usually exhibit a polished or
13 well as master sample to R
DFMEA / GD&T production parts. brighter surface. The PCP and PFMEA should reference
what features to look for.
Review supplier manf.
Part correctly orientated and retained in the die Part to have locating holes, notches or form to ensure
14 process and error proof R
before the restrike? methods correct location.
Total

D. TRIM / PIERCE OPERATIONS AUDIT WORKSHEET

EVIDENCE / G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
Inspection reports to be available as per the PCP
15 Pierced holes sizes within GD&T tolerance. Review part data to GDT requirements. R
Frequency of dimensional report to be verified.
Refer to the Process Control Plan and verify frequency
All holes present in part per latest math level Review part to and error proofing controls are in place.
16 R
release. CAD/Attribute Inspection Measurement frequency needs to be verified as per the
Process Control Plan.
Physical review of current
No surface distortion or pull back resulting from Refer to dimensional report and ensure the area conforms
17 part compaired to master R
piercing / trimming operations. sample. to the GD&T form tolerance.
 Trim / pierce direction my be specified in order to
Correct pierce / trim direction where specified per
18 Review GD&T / DFMEA safeguard wire harnesses, airbags, etc..from chaffing or R
DFMEA / GD&T
burrs and my have a 9/10 severity level.
Production gauge should have go-no-go checks for
Review parts on certified
19 Pierced holes sizes within GD&T tolerance. gauge
min/max hole sizes. Gauge should have stab pins which R
incorporate possitional tolerance for holes.
Total

E. MASTER SAMPLE - APPEARANCE AUDIT WORKSHEET

EVIDENCE / G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
Review Master sample to Ask supplier to provide master sample which is at latest
A master sample at the latest engineering change
20 latest released math and or engineering level, this can be confirmed by referring to R
level to be retained. drawing the latest math file, and GD&T drawing .
Parts with surface finish requirement are to be Reference Sheet Metal Supplier with class "A" requirement should have Global
21 maintained to the level attained and recorded at Surface Quality Approval. surface buy off sheet at PPAP. Does cuurent part R
PPAP Zebra line buyoff. conform to surface quality level at buy off?
Total

F. CAPABILITY STUDIES PQC / KPC AUDIT WORKSHEET

EVIDENCE / G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
Capability studies to be conducted on KPC's, Review Data All PQC's, KPC's and DR's to have capability studies
22 R
PQC's and DR's per the GD&T? Documents/GD&T conducted. Refer to suppliers dimensional reports.
Review PCP to verify frequincy of data collection. Have
Supplier to collect ongoing data on parts with Review Data suplier provide data showing data being collected at
23 R
PQC's or KPC's and maintain required capability. Documents/GD&T required intervals and reaction if data shows out of spec
or trending out of spec conditions.
If no PQCs or KPCs are on the GD&T drawing, request
Where no PQCs' or KPCs' exist on the drawing,
Review Data input from DRE to identify important critical areas on the
24 have all important features been identified and are Documents/GD&T
R
part. Once identified request the supplier to perform a
they being monitored.
capability study.
Total

G. ERROR PREVENTION AUDIT WORKSHEET

EVIDENCE / G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

Each die set to have Standard Operating Procedures

Die / press set up procedures available to Review suppler set up
available. The Process Control Plan and PFMEA need to
25 operators and to include error prevention procedures and who has R
authorization to modify make reference and the first off part needs to be
verification process.
approved prior to running volume production.

Method for confirming correct selection of program
26
in cases of automated press lines
Check for part no./ frequency wise program log. Check for
Review Die Set Up control on program accessibility.
R
Procedures Refer to Process Control Plan and PFMEA to ensure the
necessary controls are in place

Review supplier tool line up

Documentation available that identifies which Supplier should have available a list showing all stations
27 and have them show where R
stations have error prevention. there is error proofing. with error prevention devices or features.

Error prevention must be verified at the start of every

Red Rabbit, 1st off,
Error prevention verification to be conducted at the shift, it may also be checked periodically throughout the
28 infrequency/last off R
start of every shift or after system down time. inspections shift. Refer to the Process control plan and frequency of
checking is being followed.
Review
Supplier to conduct 1st off, last off, and in process
29 process/documentation Review process and approval to run process R
checks during production at a frequency per PCP work instructions
Clearly marked bins with
Process required to segrigate discrepent product
30 lock out. Material handler Locked bins, batch and hold process, quarantine area. R
from good shippable product auot reject process.
Total

H. TOOL/EQUIPMENT MAINTENANCE AUDIT WORKSHEET

EVIDENCE / G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
Review maintenance
records and process
Equipment spare parts are carried to ensure continuity of
supplier uses to
production if there is a breakdown. It is even more critical
Critical spares for dies/press equipment to be determine requirement
31 if the equipment was manufactured and imported from R
maintained in inventory. for spare parts. Does
overseas. Check inventory for spares and what is the
supplier have a
longest lead time on the spare parts.
contingency plan in the
event of a break down?
Preventative maintenance is required to ensure quality
parts and minimize equipment from failing and disrupting
Supplier to utilize a preventative maintenance Review supplier
32 continuity of supply. The supplier must have a R
plan/schedule? documentation
maintenance schedule that is signed off once completed.
Review schedule and documents.

Stamping suppliers typically have more than one press of

Review supplier
Supplier to develope a contingency plan for size and tonnage required. Verify with the supplier the die
33 documentation and R
machine or equipment breakdown. can be used in other presses. Part must be PPAP'd in
escalation process
alternate presses before shipping parts to GM.

Total

I. GAUGING AUDIT WORKSHEET

EVIDENCE / G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
Gauge datum pins and nets to match size and Physical inspection of Refer to the Gauge calibration report and GD&T to ensure
34 R
location as indicated on GD&T. gauge verified to GD&T the pins are built to the correct tolerance.
Review gauge Each gauge is verified by checking it on a CMM. Refer to
35 Gauge to have been verified via 3rd party. documentation at buy off or the Gauge calibration report which should not be older R
at latest certification. than 12 months.
Review gauge
Supplier to utilize a gauge maintenance and re- documentation at buy off Ask supplier to show gauge maintenance review process
36 R
certification process. and how often supplier and annual gauge certification records.
rechecks gauge on CMM.

Visual review of gauge The operator must be able to understand the Standard
37 Gauges usage instruction to be available. instructions to assure they Operating Procedures and must be available to the R
are clear and concise. operator while checking the part.

Visual Review of where If datum pads are damaged on the gauge, the parts may
Datums to be clearly identifiable and free of how does suppler store be incorrectly identified as rejects. Refer to the
38 R
damaged. gauge when not in use to preventative maintenance schedule for calibration
prevent potential damage records.
 Gauge to be kept updated to the latest engineering Verify Math and review The gauge must be identified with the latest part number
39 suppliers documentation for R
change level. gauge changes and Engineering design level.
Total

J. Finish Part Shipping AUDIT WORKSHEET

EVIDENCE / G
Enter the requirement /Standard DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
Rust inhibitors are used to protect stampings while in
storage or transit . Supplier to use only rust inhibitors
Approved rust inhibitors or other means to be used
Review of parts and found on the GM Approved Material list. Fluids or
40 where appropriate during WIP or finished goods process control plan
R
coatings not on the list may interfere with welding
storage?
operations or contaminate the paint line etc.... Refer to
the Process Control Plan.
Uncoated stampings if subjected to moisture may start to
Product in storage or staged for shipment to be show evidence of rust or corrosion. The supplier must
Visual Inspection/review of
41 protected from the elements and sources of warehousing
protect against any exposure to moisture. Verify the R
condensation and high humidity. material flow is being followed and shown on the Process
Control Plan and PFMEA.

Review supplier Stampings must be shipped in the correct packaging at

Product shipped to GM to be in GM
42 documentation for the approved pack density to ensure they are not R
Containerization approved dunnage. approved container/bins damaged as stated in the packaging approval document.

Review warehouse work Some parts have a shelf life does the Process Control
43 Supplier to follow FIFO? instructions and process
R
Plan / PFMEA capture this and is it being followed.

Labels should only be Stampings may have Left and Right and suppliers often
printed when container part
Supplier to have an error proofing process for supply parts with incorrect labelling. Follow the Process
44 bin is ready for shipment. R
labelling. No labels printed in Control Plan / PFMEA is there an opportunity for the
advance supplier to implement error proofing.

Returnable packaging may be damaged and not

Supplier to ship parts only in debris free, damage effectively protecting parts during transit. How does the
Work instructions/supplier
45 free dunnage and report any issues or damage to process
supplier ensure damaged or packaging is not being used R
GM. and is it referenced on the Process Control Plan /
PFMEA.
Direct ship stampings shall have Julian Date and lot
number on stamping. Final Assemblies must have date
46 All product requires Lot or Component traceability Review of actual part R
stamp, part number, and shift number marked on part in
visible area
Total

Sections Percent of compliance Results

A. COILS/BLANKS 0% RED
B.FORM 0% RED
C. RESTRIKE OPERATION 0% RED
D. TRIM / PIERCE OPERATIONS 0% RED
E. MASTER SAMPLE - APPEARANCE 0% RED
F. CAPABILITY STUDIES PQC / KPC 0% RED
G. ERROR PREVENTION 0% RED
H. TOOL/EQUIPMENT MAINTENANCE 0% RED
I. GAUGING 0% RED
J. Finish Part Shipping 0% RED

If any of the single sections is rated RED, overall 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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Changes Log:
Date Version Description Who
10/1/2021 1 New audit released Kent Clor / Pete Drellick