GM 1927-16a Coating Process Audit

7/22/2019 GM 1927-16a Coating Process Audit

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Auditor: Date:

Supplier: Location:

Duns: Part Name:

QuestionNumber Question Requirements and Guidance Objective Evidence N/A Satisfactory

1

Are employees trained

(supervisors, operators, job

setters, inspectors,

repairperson etc) ?

Monthly reviews and employee sign-off.

Review employee training records &

verify employee/management sign-off.

2Is there standardized work for

each leak test operation?

Review job instructions. Site

Procedures / Control Plan. Review

worksheets and verify visuals are in

place.

3Is there a written specific

process control plan for all

active process?

Review Process Control Plan and

Identify all of the manufacturing steps.

(Including cycle time, temperature, etc)

4Is there a dedicated and

qualified expert on site?

5Is work area clean and free of

outside elements?

Review plant cleanliness and

housekeeping to ensure the work

environment is free of contamination.

(see Contamination Process Audit)

6

Is there an air refreshment

and air quality monitoring

systems to avoid vapour

pollution of the baths?

7

Are there proper protections

against hazardous chemical

and enviroments?

8

Are all process flowness being

managed with PLC control(one piece follow)?

9 Are PM records up to date? Review PM logs and worksheets.

10

Is there a visual check in

place to verify material

certifications, pack slip, and

label part numbers?

Review customer bar code id, certificate

of analysis and each bin/container.

GM Process / Part Speci f ic Au dit

Process Specific Audit: Coating

Version: 1.0 Issue Date: 24Jun09

General

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Auditor: Date:

Supplier: Location:

Duns: Part Name:


GM Process / Part Speci f ic Au dit



11

Is there a system in place to

review and address customer

concerns?

The facility shall document customer

concerns along with action plans.

12

Are machinery, equipment,

and gages certified? Are GMS

principles being used?

(Gages marked in optimum

range?)

Annual Certification by 3rd Party.

Review Certification records.

Visually inspect gages.

13 What type of test method is

utilized?

Review requirement for coating

thickness, corrosion resistance,

adhesion, curing, color, and gloss.

1

Is there a process in place to

verify correct parts are

loaded?

Review error proofing process.

2


ensure part carrying fixtures

protects unit against damage

and/or mutilation?

Review carrying fixture PM.

3

Are conveyors and

transmission systems in good

form and work properly? well

designed and suitable for the

parts?

4Are carrying fixtures stored

properly?

5Is there a process in place toensure part carrying fixtures

provides for adequate

coating?

6

Is there a procedure in place

for appropriate loading of

units?

Review drawings and/or specifications

to ensure adequate loading angles,

directions, and flatness.

7Is the loading process

designed for traceability?

Loading

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Auditor: Date:

Supplier: Location:

Duns: Part Name:


GM Process / Part Specif ic Audit



1Is material concentration

verified?

Review lot numbers, control plans and

log sheets.

2

Are temperatures and process

times recorded and verified

per process requirement?

Review temperature gage.

3


verify cleaning solutions as

suitable for removing all

process soils as demonstrated

by water break?

Review lot numbers, control plans and

log sheets.

4


ensure adequate

pressure/agitation?

5


verify cycle time to ensure

appropriate exposure to pre-

treatment?

Review control plan, logs and

worksheets.

6

Is corrosion inhibitor

concentration regularly

checked/inspected?

Review control plan, logs and

worksheets.

7


verify coating weight, crystal

size, and fluoride

concentration?

Review control plan and customer

requirement.

8 What is the dump schedule forcleaning, rinsing, and sealing?

Review chemical manufacturerguidelines.

9

Is the temperature in the oil-

dirt removal bath unit under

control i.e. within +/-5C and is

as required ?

Pre-treatment

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Auditor: Date:

Supplier: Location:

Duns: Part Name:





10

Is oil - dirt removal done by

basic and acidic bathings and

intermediate washings and if

necessary manual removal?

11

Is there a final rinse and is it

monitored for presence of

bacteria (for plastic substrate)

?

Review control plan/log sheets.

12

Is there an appropriate

process for verifying adequate

sealing coverage?

Review customer specifications.

1

What is the frequency for air

temperature monitoring and

control?


2

Is there an appropriate

procedure to ensure effective

dryness?

Review each lot.

3

Are oven set points and

process time recorded and

verified as meeting the

process requirments?


1

What is the procedure to

verify coating is correct and

meets compositional

requirments?

Review customer specifications.

2What is the process to monitor

gun pressure?Review PM logs and worksheets.

3

What is the process to monitor

appropriate coverage of the

parts?

Review Control plan


booth humidity?Review control plan and log sheet

Dry Off

Coating Spray

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Auditor: Date:

Supplier: Location:

Duns: Part Name:





5What is the process to ensure

gun functinalities?Review PM logs

6

Is there a process tmonitor /

inspect feed hoses for

excessive bends and kinks?

Review control plan and log sheet

7What is the process to check

flow direction?Review control plan

8

Is there a notification systemm

in place in case of system

failures?

Review Control plan

9What is the dump schedule for

coating?Review cpntrol plan

10

Are filter checked frequently

for sizes and type?

Review manufacturer recommendations

and control plan

11What is the process to verify

paint performance?Review control plan

1

Are oven temperatures, set

points, and limits monitored

and documented?

Review material specifications


conveyor speed?Review control plan

3

What is the process to monitor

booth temperature and

humidity?

Review control plan

4Is there a process to monitor

paint adhesion?

Review control plan and color change

requirements

5

Is there a procedure in place

to check and maintain proper

cure time?

Review coating supplierrecommendations

1What is the process to

maintain part racks?Review control Plan

2Are parts package to minimize

mixed parts?Review control Plan

Unloading

Cure Oven

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Auditor: Date:

Supplier: Location:

Duns: Part Name:

Question

Number Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Sat

GM Process / Part Speci f ic Audi t


Assessm


3Is there a re-work procedure

in place?Review control Plan

4

Is there a labelling process in

place for container

identification?

Review control Plan

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Needs Immediate

Action

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Needs Immediate

Action

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Needs Immediate

Action

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Needs Immediate

Action

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Needs Immediate

Action

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Needs Immediate

Action

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Process Performance SUPPLIER ACTION PLAN REPORT

Supplier Start Date:

Location Rev. Date:

Duns Grad Date:

Commodity Program:

Prepared by:

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)

TOTAL TOTAL

0 0

ITEM Priority Group ACTION ITEMACTION

LEADER

DATE

OPENED

TARGET

CLOSE

DATE

ACTUAL

CLOSE

DATE

LAST

UPDATE1 2 3 4 5

1 0

2 0

3 0

4 05 0

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

19 0

20 0

21 0

22 0

23 0

24 0

25 0

26 0

27 0

28 0

STATUS

Creativity Team

SQE

SQE Phone & Fax

Manager:

Group:

Oldest

MoRece

215680469.xlsx.ms_office Printed: 3/8/2014


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Process Performance SUPPLIER ACTION PLAN REPORT

29 0

30 0

31 0

32 0

33 0

34 0

35 0

36 0

37 0

38 0

39 #REF!

40 #REF!

41 0

42 0

43 0

44 0

45 0

46 0

47 0

48 0

49 0

50 0

51 0

52 0

53 #REF!

54 0

215680469.xlsx.ms_office Printed: 3/8/2014


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If the question is not applicable then the auditor shall place a check mark in the "N/A" Assessment column.

If the observed evidence is in compliance to the question then the auditor shall note the evidence in the "Observed

Evidence" column and place a check mark in the "Satisfactory" column.

If the observed evidence is not in compliance to the question then the auditor shall note the non-compliance

evidence in the "Observed Evidence" column and enter into the "Not Satisfactory" column specific actions to

address the issue. This information will transfer automatically to the Action Form on the corresponding line

number. The auditor shall assign appropriate single point personell and timing to address the issue.

When non conforming product is identified during the audit the auditor shall place in the "Needs Immediate Action"

column specific actions to address the issue. This information will transfer automatically to the Action form in the

same Item No. line. The auditor shall assign appropriate single point personell and timing to address the issue.

"Needs Immediate Action" issues shall be addressed prior to the auditor leaving the facility.

Documents

GM 1927-16a Coating Process Audit