LPA LAYER 2 QUESTIONAIRRE:

AUDITOR: AUDIT AREA: DATE PART NUMBER(S) AUDITED:

Page 1 of 3

AUDIT CRITERIA
Safety:

REACTION PLANS
Does area reflect in job being performed? If not, contact supervisor immediately If not, stop production and remove any safety hazards, clean any spills, and have the operators clean the area to ensure a safe work environment. If not, STOP the job immediately and contact maintenance and engineering immediately. If not, STOP the job immediately and contact maintenance and engineering immediately. If not, STOP the job immediately and contact maintenance and engineering immediately. If not, STOP the operator immediately and contact supervision immediately.

ISSUES/COMMENTS/SUGGESTIONS

S1

Is the Area Safe and the operator wearing Safety glasses? Is the area free of oil/water on the floor, and loose cords or wires, etc. and all machines are clean, areas not cluttered, Do all safety curtains and emergency stops work effectively? Do all safety curtains have the required tool for verification? Is the safety curtain tool attached to the equipment it is to verify?

S2

S3

S4

S5

Are the operators wearing all S6 required PPE per the Work Instructions posted for the job?
Process :

P1

P2

P3

P4

P5

If not, contact supervisor immediately & Has the 1st Piece been signed off Quarantine All Parts. Look @ Inspection and available in its correct location? Checklist. Review setup sheet for correct materials. If Do Materials meet Production not, contact supervisor immediately & requirements? Quarantine Parts. If not, contact supervisor immediately & Are rejected parts identified/tagged Quarantine Parts. Look around work areas correctly and in proper container? for unidentified parts. Verify that operators are following Work Are Operators following Instructions posted at their work station. If Standardized work Instructions? not, notify supervisor and quality. If not, contact quality to develop. Ask Are boundary samples readily Operator where they keep boundary available? samples.

Look up training Matrix in Plex and Verify Are trained operators at the work all operators are trained to the job they are P6 station as per training matrix located performing. If not contact supervisor to add in Plex? the training level to Plex. P7 Is the line producing to the Appearance Standard? If not, contact supervisor immediately & Quarantine Parts. Please review Work Instructions & review how glue is being applied to verify.

P8 Is glue being applied correctly?

P9

Are all repairs processed to go back into the cell for final inspection and Please verify all repairs are going back verification over error proofing prior through normal process for inspection. to shipment? Please review the PFMEA and the consequences of shipping a nonconformance to the customer.

Are the operators aware of the P10 consequences of shipping a nonconformance to the customer?

Has the Preventive Maintenance Contact Maintenance and Supervisor to PM P11 been completed on all equipment in equipment immediately. this cell?
Error Proofing

Are there Error Proofing Devices in E1 this process? Check one "Red Rabbit" for effectiveness.

If no Error Proofing devices in cell, mark N/A. If there are Error Proofing devices, verify one works as intended, if it does not work, contact supervisor immediately & Quarantine All Parts

If no Error Proofing devices in cell, mark Are we verifying these Error Proofing N/A, if No log contact Quality Engineer to Devices and recording in a log? develop. If no Error Proofing devices in cell, mark Is there a certification sticker on the E3 N/A, if No certificate contact Quality Error proofing device? Engineer to develop. Has the error proofing device been If no Error Proofing devices in cell, mark E4 added to the Master Error Proofing N/A, if Not in the log contact Quality log? Engineer to update. E2

TS-PRC-8222C - Layer 2 questionnaire

Issue Date:06/04/11

LPA LAYER 2 QUESTIONAIRRE:

AUDITOR: AUDIT AREA: DATE PART NUMBER(S) AUDITED:

Page 2 of 3

AUDIT CRITERIA

REACTION PLANS

ISSUES/COMMENTS/SUGGESTIONS

If no Error Proofing devices in cell, mark Are there additional opportunities for N/A, if Not leave this blank, if Yes, provide E5 Error Proofing? a detailed explanation in the corrective action section.

TS-PRC-8222C - Layer 2 questionnaire

Issue Date:06/04/11

LPA LAYER 2 QUESTIONAIRRE:

AUDITOR: AUDIT AREA: DATE PART NUMBER(S) AUDITED:

Page 3 of 3

AUDIT CRITERIA
Product

REACTION PLANS
Verify check sheet is filled out correctly and there is no data out of spec. If not, notify supervisor immediately. If there is data out of specification Quarantine All Parts & contact Quality.

ISSUES/COMMENTS/SUGGESTIONS

Are the operators using the part C1 gauge for all dimensional requirements?

Verify check sheet is filled out correctly and there is no data out of spec. If not, notify Are we verifying SPC as required by C2 supervisor immediately. If there is data out the customer? of specification Quarantine All Parts & contact Quality. C3 Verify correct packaging is being used and Is the correct packaging being used the labels are correct. If not, contact and is the labeling correct? supervisor immediately & Quarantine All Parts. Review parts at shipping container & verify they are good parts and meet customer needs. Verify part fits the gauge as required. If not, contact supervisor immediately & Quarantine All Parts.

Do appearance items meet C4 Customer Specs, eg. gouges, short shots, color, etc? Does the part fit the gauge for all C5 dimensional requirements as required by the customer?
Quality System

Are all ACTIVE quality alerts posted Stop Job immediately and train all current Q1 in the cell signed by operators operators to the Quality Alert. currently in the cell? Are all quality alerts posted in the cell Remove all inactive Quality Alerts and Q2 still active (not expired)? place on Quality Manager's desk. Verify Quality Alerts are still active and not expired, stop Job immediately and train all Are all active quality alerts posted in Q3 current operators to the Quality Alert and the cell being followed? contact Operations Manager and Supervisor. Q4 Q5 Are gauge calibration Tags current? Quarantine All Parts & contact Quality. Check one. Are Inspection Check Sheets being filled out completely and correctly? Are shipping containers free of debris, rocks, etc.? Notify supervisor immediately.

Remove the container and contact materials immediately and replace with a clean container. Have all Corrective Actions been Contact Manufacturing Manger to Q7 completed? determine competion timing. Is there a Job book available for the Contact Quality to develop and or print and Q8 operators. place a new job book for this cell. Are the Level 1 LPA audit being Contact the Manufacturing Manager for Q9 completed as required? resolution. Q6
Comments and suggestions for improving this audit sytem, questionnaire, or format.

Please state improvement suggestions for each area, either updates to the I1 questionnaire for layer 1 and 2, system improvements, or process changes to improve parts or reduce costs.

Non-conformance

LEGEND YES-

NO- X

TS-PRC-8222C - Layer 2 questionnaire

Issue Date:06/04/11