Professional Documents
Culture Documents
Supplier:
Parikshit
Plant location:
SQ
Bangalore, India
NPO Number:
Vane
Customer / Application
795030-0009
Drawing revision
Dash revision:
Audit date:
Objective of the Audit:
Process audited:
Statement
All process against PFD, Control plan and PFMEA are audited.
Date
Initial audit
Number of criteria
1
2
3
115
Number of criteria
audited
Audit rating
Capacity
(OK/NOK)
Run@rate decision
(Passed/Open/Failed)
115
100.00%
OK
pass
Validation audit
casting
Negative Points
Y
machining
<--- (print Y or N)
assy
others
Status
PASS
<--(print Y or N or N/A)
Agreed ramp up plan?
--> Y
(acceptation record from buyer / launch buyer)
41667
34722
43806
PPAP decision
Full approval
Interim / Level
Rejected
NA
Interim recovery worksheet prepared and agreed with the supplier (Y/N)
Not assessed
Y/N
Y
SYNTHESIS BY CHAPTER
AUDITOR RESPONSIBLE:
Parikshit
EDITION: 2009
AUDIT DATE:
PROCESS AUDITED:
All process against PFD, Control plan and PFMEA are audited.
PAGE:
PART AUDITED:
Vane
2
Parikshit
0%
20%
40%
60%
80%
28
TOTAL
28
TOTAL
13
TOTAL
21
TOTAL
20
TOTAL
11
TOTAL
22
TOTAL
115
100%
0%
20%
40%
60%
80%
13
100%
0%
20%
40%
60%
80%
21
100%
4- Equipment ("E")
Number of criteria per rating
0
1
2
3
0%
20%
40%
60%
80%
20
100%
0%
20%
40%
60%
80%
11
100%
0%
20%
40%
60%
80%
22
100%
GLOBAL
0%
20 %
4 0%
6 0%
80%
1 00 %
Process Operations
Process Name
OP Number
Molding
OP1
1600 / hr
Debinding
OP2
9000 / 7 hrs
Sintering
OP3
50000 / 24 hrs
Thermal Sintering
OP4
40000 / 8 hrs
Profile Grinding
OP5
260 / hr
Drilling
OP6
600 / hr
Barrelling
OP7
900 / hr
Ultrasonic Cleaning
OP8
440 / hr
SYNTHESIS BY AREA
EDITION: 2009
AUDITOR RESPONSIBLE:
Parikshit
AUDIT DATE:
PROCESS AUDITED:
All process against PFD, Control plan and PFMEA are audited.
PAGE:
PART AUDITED:
Vane
3
Parikshit
Reception / Shipment
0
0%
20%
40%
60%
80%
25
TOTAL
25
TOTAL
37
TOTAL
31
TOTAL
93
100%
0%
20%
40%
60%
80%
37
100%
Quality
0
0%
20%
40%
60%
80%
31
100%
GLOBAL
0%
20%
40 %
6 0%
80%
0
93
100%
100%
not required
Not audited
1
2 22 0
PPAP Requirements
Team Feasibility Commitment or APQP open issue list with all points closed can replace TFC
Process Flow Chart / Should be identified the machines approved through current ppap and their placement
FMEA review evidences / risks >32/50 with actions, due date, responsibles, also CICs and KCCs identified
Control Plan / all characteristics from drawings and applicable standards controlled, CICs and KCCs identified
Measurement Systems Analyses (e.g. R&R) for all systems used to measure KCC and CIC, including BIAS when necessary
1
1
1
1
1
Measurement protocols validation or correlation results (important features, including attribute gages, mandatory
Primary components PSW (full approved by Honeywell or, if not applicable, at least by supplier)
Functional tests evidence (like pouring simulation for casting) , when required
Honeywell property tooling identification evidences (e.g. pictures with toolings labels)
Shipping packaging specification, including pictures and materials used
Honeywell production site (named in PSW) approval for packaging specification
Quality Laboratory Competence 3rd party evidence (if not ISO/TS certified)
1
1
1
1
1
1
1
Microstructure analyse for castings or where required by Honeywell standards, relevant in report
with number of cavities / toolings and parts complexity
Sample products when requested, ISIR (Initial Sample Inspection Report) relevant number of parts
Process Capability Studies / on CICs and KCCs, sampled from all toolings combinations, for HTT relevant statistic
characteristics being followed through PCD in SCC, otherwise being used Excel approved forms, normality tests being necessary before
using capability formulas
1
1
1
1
1
TOTAL
24 lines, confidence:
Form 5407_attachment E_rev C
100%
795030-0009
Supplier Monitored
Supplier Name: INDO-US
J'
VANE
Program:
GTD 12
Supplier Data
A.
PURCHASED CAPACITY
(PC) (quantity / week):
B.
please fill in all bordered blank cells to enable MAX CUSTOMER DEMAND
(MCD) [quantity / week]:
formulas
Workdays of Honeywell T.T. plant
[days / week]:
34722
300
700.0%
168.0
Planned
(by the supplier)
Date of Run@Rate:
Downtime during Run@Rate period
20/05/2014
8.0
minutes
hours
minutes
hours
10
0.17
10
0.17
2.
lunch
30
0.50
30
0.50
3.
maintenance
part # changeover /
setup time
0.00
0.00
0.00
0.00
5.
unplanned
0.08
0.08
6.
Total [1 through 5]
45
0.75
45
0.75
7.
% Downtime
{=(H6 /G )}
[%]
{=(F*(1-H7)
[hrs]
J.
9.4%
9.4%
152.25
152.25
2090
1.
Total Parts
[# of ]
2100
2.
Rejected
[# of ]
3.
Net Good
2099
2086
4.
Net Parts / Hr
262.38
260.8
ACTUAL DC
{=J1-J2}[#
{=J3 / G}
of ]
[# / hr ]
[quantity / day]
MCD
44079
43806
34722
41667
262836
208333.333333333
208333.33333333
Capacity
Quality
Final Status
PASS
OPEN (Failed QTC)
OPEN (Failed MSV)
FAIL
PC
264474
Comments:
Action plan for capacity presented
20/05/2014
8.0
1.
4.
41667
[quantity / day]:
24
H.
Daily volume
100.0%
G.
208,333
not required
not audited
Criteria
RECEPTION / SHIPMENT
NA: Not Audited
NR: Not Required
'0: Satisfactory
1: Potential failure: Action required
2: Non-conformity without impact on current production: Action required
3: Non-conformity with impact on current production: containment + action required
0
1
0
2
0
3
0
1
0
2
0
3
Lapsing/expiration
RD2 - Are the rules of lapsing/expiration defined (eg: elastomere for membranes, sand-cores, )?
- Is any expired good on the shelve? (or affected by environment but still in validity)
RD3
Flow
- Is a flow defined from raw material arrival up to supply to production lines?
- Is FIFO (First In First Out) defined?
- How FIFO is affected by parts reintroduced in flow by quality / tooken for final control
Non conformities
- Is the process defined to isolate non-conform components?
RD7 - Are the roles and responsabilities defined for scrap boxes management?
- Are the roles and responsabilities defined to manage storage of non-conforms?
- Is a rework procedure defined for components / finished goods? Agreed with HON TS?
0
NA
0
NR
7
0
RW3
Knowledge/respect of procedures
- Is the control plan known and followed?
- Is the contingency plan / EPC known?
- Is the visual defect catalogue known?
RM2
0
NA
0
NR
4
0
Quality records
- Are the controls done as per working instructions and control plan?
RM3 - Are associated records available?
- In the history of records, if non-conformity has been detected, has any containment activity been
rolled-out?
RM4
Product packaging
Is the packaging adequate to ensure product integrity?
0
NA
0
NR
RE2
Capability/MSA
- Have the gages R&R studies been performed?
- Is the gage device adequate to measure the parameter?
- Does the manufaturing process demonstrate required capability as per QCI-9310-190?
0
2
0
3
0
1
0
2
0
3
4
0
0
1
25
0
100%
0.333
0
2
0
0
3
0
Non conformities
RE5 - Are the non conform parts identified, segragated and separated?
- Is there a quarantine area established, secured and properly identified?
Equipment : sub- total
N
Criteria
house keeping (conditions)
0
1
5
0
1
0
NA
0
NR
5
0
RC1
RC2
Lighting
- Is the lighting adequate in the quality inspection areas?
Flow
- Is the flow adequate to avoid mix, damages?
RC3 - Is FIFO respected?
- Is the single piece flow implemented? If not, is the justification acceptable?
- Is an access to all boxes (to pick the oldest)?
0
NA
0
0
NR
0
not required
not audited
Criteria
Lapsing/expiration
- Are the rules of lapsing/expiration defined (eg: elastomere for membranes, sand-cores, )?
Flow
PD3 - Is the flow between the operations defined?
- Is FIFO (First In First Out) defined?
Contingency plan
PD4 - In case of poka-yoke, machine or specific gage failure, is a procedure defined to contain the
process?
PD5
Gages & machines (set-up, maintenance, use, calibration) for the specific part
- Is maintenance plan adhered to workstation?
- Are the machine settings parameters defined?
- Are the tool lists defined?
PD7 - Is the set-up and change-over procedure defined?
- Are the parts used for set-up managed in adequate manner (identification, ...)?
- Are the acceptance limits used for set-up taking into account the capabilities for each parameter?
- Is a procedure defined to ensure that gages are identified/calibrated periodically?
- Is the plan to manage/maintain/calibrate the poka-yoke clearly defined?
PD10 Process flow has all elements needed ? (including P-Y, rework processes)
Are all the failure modes identified in the P-FMEA ? (see each dwg. + doc. statement)
- Are all RPN<32 (50) ?
Rework
- Are the parts susceptible to be reworked isolated, identified and protected against damages?
PD13 - Which are the possible reworks?
- Are the operators trained according to approved documents?
- How a reworked part is identified in HON TS plant?
Non conformities
- Is the process defined to isolate non-conform components?
PD14 - Are the roles and responsabilities defined for scrap boxes management?
- Are the roles and responsabilities defined to manage storage of non-conforms?
- Is a rework procedure defined? Agreed with HON TS?
PD12
1
NA
0
NR
13
0
Specific qualifications
PW1 - If specific habilitation is required: does the operator have valid habilitation?
- Are enough people trained to cover the expected capacity?
Knowledge/respect of procedures
- Is the working instruction known?
- Is the control plan known and followed (including filling of record-sheets)?
- Is the contingency plan known?
PW2 - Is the management of poka-yoke known?
- Is the visual defect catalogue known?
- Is the procedure of non-conformity management known and applied?
- Is the identification+storage procedure respected (eg: color boxes ...)?
- Are the records requested by the control available?
Quality risks
- Is the operator aware of quality risk at his operation?
- Does the operator know what is the impact on the next operation?
PW3 - Does the operator know what is the impact on the final product?
- Is the operator aware of defined reaction procedure in case of non-conformities?
- Is the operator aware of purpose of the poka-yoke?
- What are the risks of having one gage out of calibration?
Quality records
- Are the controls done as per working instructions and control plan?
PM3 - Are associated records available?
- In the history of records, if non-conformity has been detected, has any containment activity been
rolled-out? Was it validated by qualified personnel?
PM4
Product packaging
- Is the internal operation packaging adequate to ensure product integrity?
0
NA
0
NR
4
0
0
1
0
2
0
3
0
1
0
2
0
3
Applicable to OP no.
Non conformities
- Has the normal control plan identified non-conformities?
- Has a pass-thru defect been detected out-side normal control plan?
- If yes, are the non-conform parts identified as per supplier procedure?
- Has proper containment plan been put in place?
- Were the non-conformities identified in the P-FMEA?
PM8
PE1
0
NA
0
NR
8
0
0
1
0
2
0
3
0
1
0
2
0
3
4
0
0
1
37
0
100%
0.333
0
2
0
0
3
0
Capability/MSA
- Have the gages R&R studies been performed (at least for all KCC and CIC)?
- Is the gage device adequate to measure the parameter? (eg: 3 points contact for circularity)
PE2 - Does the manufaturing process demonstrate required capability as per QCI-9310-190?
- Are statistical records documented? Analyzed? And corrective actions undertaken in timely manner?
- Are Scrap rate and rework at target (10% for cast and 5 % for machined)
- Are the equipment in place and fully operational (Final layout, automatic mode,....)
PE4
Contingency plan
- In the subsitute mode in case of poka-yoke failure available?
PE5
- How can be replaced a gage in case of accidental failure?
- What if a critical component of machines is failed and replaced by a different one?
PE6
Non conformities
PE8 - Are the non conform parts identified, segragated and separated from the manufacturing process?
- Is there a quarantine area established, secured and properly identified?
0
NA
0
NR
Lighting
PC2 - Is the lighting adequate to perform visual inspection?
- Has the operator the necessary visual accuracy ?
PC3
Flow
- Is the flow adequate to avoid mix, damages?
- Is the single piece flow implemented? If not, is the justification acceptable?
- Is the ergonomy of the station adequate?
8
0
1
0
NA
1
0
NR
0
not required
not audited
Criteria
QUALITY DEPLOYMENT
NA: Not Audited
NR: Not Required
'0: Satisfactory
1: Potential failure: Action required
2: Non-conformity without impact on current production: Action required
3: Non-conformity with impact on current production: containment + action required
Organization - procedures
QD1
QD2
Flow
- Is the flow for parts entering in quality department defined?
- How the parts are identified (process step, stage of inspection, date) ?
QD3
QD4
QD5
QD6
Gages & machines (set-up, maintenance, use, calibration) for the specific part
Are the gages seen on workstation recorded in a database ensuring periodic calibration and
conformity?
QD7
QD8
Non conformities
- Is the process defined to isolate non-conform components?
- Are the roles and responsabilities defined for scrap boxes management?
- Are the roles and responsabilities defined to manage storage of non-conforms?
- Is a rework procedure defined? Agreed with HON TS?
0
NA
0
NR
Specific qualifications
- If specific habilitation is required: does the operator/technician have valid habilitation ?
0
NA
0
NR
5
0
Quality records
- Are the controls done as per working instructions and control plan?
QM3 - Are associated records available? (including interpretation)
- In the history of records, if non-conformity has been detected, has any containment activity been
rolled-out?
0
2
0
3
Product packaging
- Is the internal operation packaging adequate to ensure product integrity?
0
1
QM4
0
3
QM1
0
2
Quality risks
- Is the operator aware of quality risk at his operation?
- Is the operator aware of defined reaction procedure in case of non-conformities?
- How an operator can know all gage are calibrated and in validity period?
0
1
Knowledge/respect of procedures
- Are the procedures known?
- Is the control plan known and followed (including filling of record-sheets)?
QW3 - Is the contingency plan known?
- Is the procedure of non-conformity management known and applied?
- Is the identification+storage procedure respected (eg: color boxes ...)?
- Are the records requested by the control available?
QW4
8
0
QE1
0
NA
0
NR
8
0
0
1
0
2
0
3
0
1
0
2
0
3
3
0
0
1
31
0
100%
0.333
0
2
0
0
3
0
Capability/MSA
- Have the gages R&R studies been performed? (results >10% or 30% contained)
QE2 - Is the gage device adequate to measure the parameter? (accuracy, specifics)
- Are statistical records documented? Analyzed?
- Are the equipment in place and fully operational (Final layout, automatic mode,....)
QE4
Substitution process
- Is the subsitute mode in case of gage failure available?
QE7
Non conformities
- Are the non conform parts identified, segragated and separated from the manufacturing process in
quality areas ?
- Is there a quarantine area established, secured and properly identified?
1
0
NA
0
NR
Lighting
- Is the lighting adequate?
Flow
QC3 - Is the flow adequate to avoid mix, damages?
- Is the ergonomy of the station adequate?
House keeping at workstation : sub total
N
Criteria
Total
Confidence Level (%) 31 lines
Global contribution of confidence level
Legend
NR : Not required
NA : Not audited
0 : Satisfactory
1 : Potential failure: Action required
2 : Non-conformity without impact on current production : Action required
3 : Non-conformity with impact on current production : Containment+action required
7
0
1
0
NA
0
0
NR
0