Questionnaire for Casting Foundries.doc

SUPPLIER QUALITY AUDIT QUESTIONNAIRE- Casting Foundries -

Date:

Supplier:

Address:

Phone No:

FAX No.:

Supplier Contact: Name & Title (Please print or type)

Signature Date

Victaulic Company (use only)

Initial Quality Audit Follow-up Quality Audit

Quality Assurance

Date Procurement Date

Preface:

This document is used for the evaluation of the capabilities and quality system of potential or current Victaulic supplier. A Quality Audit does not convey source approval or assurance of commercial business.

Please answer all questions. If you cannot answer a question, contact your Victaulic Representative.

Contents of this audit will be kept confidential.

VICTAULICSupplier Quality Audit Questionnaire – Version D

Page 1 of 10

Section І: Overall Quality Information:

1. Is your company ISO 9000 registered? Yes No

a) If yes, by what agency or registrar granting certification, to what level, and when is the expiration

date?

Please provide a copy of ISO certificate as attachment of this Questionnaire.

b) If no, are you currently pursuing ISO 9000 registration? Yes No

c) If you are currently pursuing your ISO 9000 registration, when is an audit scheduled?

d) If multiple facilities/operations exist in your company, are these also ISO certified?

Yes No

If not, please list all the facilities/operations without ISO certification as bellows:

2. Please provide the name of your Quality Assurance Manager:

Phone: Email address:

3. Please provide a copy of detailed Quality Assurance Manual for our reference.

4. What languages except English are spoken by the management representatives for Manufacturing and

Quality Assurance?

5. Do you have a supplier qualification/rating system in place? Yes No

If yes, please describe:

If not, how do you approve your suppliers and manage their quality issues?

6. How are your management kept informed of quality issues?


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7. Do you have a Quality Improvement Plan? Yes No


8. Do you have a Quality Cost Measurement Plan? Yes No


9. Do you have a procedure to periodically calibrate measurement/test equipment?

Yes No

10. Do you provide the training associated with quality system to the employees? Yes No

If yes, how?

11. Do you have the ability to exchange drawings with your customer electronically? Yes No

12. Do you perform internal audit on a regular basis? Yes No

13. For non-conforming material, what procedure is in place for corrective/preventative action?

Please describe in details and attach a copy of original records showing a recent example:

14. In the event of a field failure of the product you supply to Victaulic, who would be our urgent

contact:

Name: Title:

Phone: Email Address:

Fax:

15. Are there material recall procedures in place? Yes No

If yes, please describe in details:


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16. Do you have a workplace safety program? Yes No

17. Do you have a program to control hazardous materials or chemicals used at your facility?

Yes No

18. Do you have the proper environment permits for air/water and noise discharges from the local

authority? Yes No If yes, please attach a copy of the permit.

Section II: Incoming/Raw Material Control

1. Receiving inspection procedures (use reverse side of form if necessary):Please describe:

a) Is raw material routinely tested? Yes No

b) Frequency of tests?

c) Are raw material tests documented? Yes No

If yes, where are test records maintained?

d) Are material certifications furnished by suppliers? Yes No How often?

e) Who is responsible for initiating and tracking supplier corrective actions?

2. a) Where is raw material staged?

b) How is the material identified/labeled?

c) How is the material tracked through production?

d) What type of scrap iron/metals is used in the melting process?

e) Where is scrap iron/metals stored?


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f) Are there controls in place to prevent movement of incoming, non-conforming material into the

production system? Yes No If yes, please describe:

g) Is there a dedicated Quarantine area? Yes No

h) How is the incoming inventory used? (oldest material used first)?

3. a) Are there any storage requirements based on temperature/or other atmospheric conditions?

Yes No


Section III: In-Process Control – Molding

1. What type(s) and size (AFS#) of molding sand are used?

2. a). Describe the tests that are performed on incoming shipments of molding sand:

b). How often are test results recorded? c). By whom?

3. How is molding sand released into production?

4. Describe the type or brand, size and capacity of sand molding equipment in use:

5. Are cores made internally or by an outside supplier?


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6. If made internally, describe the type or brand, size and capacity of core-making equipment in use:

7. Describe the core-setting capabilities in use:

8. Are any tests performed on finished cores prior to production?

9. How and where are patterns and core boxes stored and maintained?

Section IV: In-Process Control – Melting

1. What testing is performed to verify material chemistry?

2. Is the melting process continuous or performed by batch processing? Yes No

3. Describe the type or brand, size and capacity of furnace equipment in use:

4. Describe the chemical treatment method in use prior to pouring:

5. Describe the test equipment in use during the melting process:

6. Describe the tests that are performed during the melting process:


Page 6 of 10

Section V: In-Process Control – Pouring

1. What testing is performed to verify material chemistry / modularity?

2. Is pouring done manually or by an automated system?

3. What type and capacity of pouring equipment is in use?

4. Describe the type or brand and size of inoculation equipment in use:

5. Inoculation is performed by the following method:

Post-delivery system

In mold treatment

In stream treatment

6. What checks and controls are in place while pouring?

7. Describe how temperature, inoculation and Mg fade time are monitored and controlled:

8. What is the procedure for tracking molds poured from a specific ladle?


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9. How is the material identified (traceable) throughout the manufacturing process?

10. a) What is the approximate number of gages used throughout the manufacturing process?

b) How often are gages calibrated? c) By whom? d) Describe the storage and distribution of gages:

Section VI: Finished Goods Control

1. Describe final inspection procedure:

2. Are checks in place for:

Visual Inspection: Yes No

Dimensional Inspection: Yes No

Markings/Color Code: Yes No

How are markings applied to the finished product?

3. Final testing to verify:

a) Material chemistry / nodularity: Yes No

b) Material strength/integrity (tensile, yield, elongation, hardness): Yes No

c) Other requirements, please indicate:

4. Do you indicate the material and specification requirement(s) as well as the inspection standard(s)

in the final inspection sheet? Yes No

Please attach a copy of the completed final inspection report for our reference.


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5. Describe how the following dimensional attributes are controlled:

Wall thickness:

What are the limits of wall thickness variations?

Ovality (out-of-roundness):

Applicable product dimensions:

Coupling Housings (key, shoulder, gasket pocket diameters):

Fittings / Valve Bodies (A, B, C and OD):

6. For finished product, please describe the method of:

Storage:

Packaging:

Section VII: Statistical Process Control

1. Do you have an on-going SPC program? Yes No

2. Is SPC utilized for significant product characteristics and process parameters? Yes No

If yes, who chooses which items are to be monitored through SPC?

3. Do your SPC control charts indicate that statistical control has been achieved and process

capability demonstrated? Yes No

(If yes, please attach a copy of a control chart that is used for a Victaulic product)

4. Are your sub-suppliers required to use SPC and provide that information?

Yes No If yes, what percentage?

5. Are all levels of your personnel undergoing any type of SPC training programs? Yes No

-- The End --


Page 9 of 10

Victaulic Company (use only)

Comments/Observations:

Conclusion:

Accept Reject On-site Audit Required Remark: On-site Audit is required for all the Follow-up Audits.

Reviewed by: __________________________

Date: __________________________


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Questionnaire for Casting Foundries.doc