GM 1927 16 Process Control Plan Audit PCPA
GM 1927 16 Process Control Plan Audit PCPA
Reason For Audit: Future Launch Current Partial Other Safety Related Part ? Yes No N/A
Type of Audit: Follow RunatRate (GM 1927 Product Validation Complete:
Initial Yes No N/A
Up 35 Attachment B)
Driver of Audit: APQP Mgmt. Plant Run @ CPIP/
Confirmation Request
Critical Request Rate Disruption Shutdown/Start
Warranty Up
Risk Supplier
Component CSL-1 CSL-2 Major
Fastener D/PFMEA DD&W Audit
Other
Check Plan
Focus of Audit: Part / (D02)
Operation / Complete Mfg. Quality System - Ongoing
Line /Cell
Assembly Machine System Documentation
Technical Information Availability
NR 1. Actual Drawing NR 2. Approved Drawing NR 3. Print Complete
NR 4. Technical Regulations NR 5. DFMEA to PFMEA
0 Total Potential 0 => NR
NR 0 Technical Information Availability GREEN 0 Element is not in place and no evidence of plans to implement
NR 0 Quality System Documentation GREEN 1 Element is not in place but a plan to implement is documented
NR 0 Quality System related to Control Plan Implementation GREEN 2 Element is in place but it is not being followed
NR 0 Quality System Implementation by Management GREEN 3 Element in place but not followed at each job or all the time
Approved Approved, but need Documentation Not Approved Follow-Up Audit Date:
In case of deviations use Supplier Action Plan Form tab.
If SQE considers to deep dive more the quality system and production floor use or refrence to GM 1927 72 Shop Floor Audit.
G
B. Quality System Documentation AUDIT WORKSHEET
EVIDENCE / G
REQUIREMENT / STANDARD:
B1 DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Score Y OBSERVATIONS
In regard to PFMEA:
REQUIRED R
G
Process Flow and Material
Process Flow Diagram is consistent with the Shop floor material process Process flow and material flow are consistent
7 Flow NR
flow
G
All process steps from the Process Flow Diagram are listed in sequence Process Flow PFMEA is being linked to the Process Flow Diagram
8 in the PFMEA, including repair and rework operations, PFMEA Assure that ALL process steps have been captured and none NR ###
are missing.
G
PFMEA shall be developed on a form based on the options provided by
9
the AIAG PFMEA / AIAG VDA PFMEA Standards (where applicable)
PFMEA Template Make sure the latest templates are being used NR ###
G
G
Reverse PFMEA Events
PFMEA risk reduction activities and meeting minutes.
Suppliers shall have appropriate preventive risk reduction projects based GM 1927 21 DFMEA PFMEA
21
on the effects of the potential problems. Gap Analysis Process and
Look for evidence on the production line or stations of reverse NR ###
PFMEA activities or improvements.
Transition Form G
Sample size and frequency are determined based on risk and Is there a history of failures in spite of existing controls?
22 occurrence number from PFMEA. Control Plan Does internal data (scrap, rework, FTQ, etc) suggest sample NR
Sample size and frequency are reviewed on regular basis. sizes and frequency are adequate?
G
The supplier shall assure that all high severity items are cascaded to
DFMEA / PFMEA /
their suppliers (Tiered suppliers)
24
The supplier should perform PFMEA Gap analysis or similar to their
Control Plan Is control data from the tier supplier reviewed and kept on file? NR ###
(Tiered suppliers)
tiered suppliers.
G
Make sure gauges/fixtures are ID Equipment taged, Calibrated
(CMM report) with certification in the latest engineering
Gauges change level.
The control methods should be continually evaluated for effectiveness of
25
process control. (AIAG APQP and Control Plan Manual / MSA)
Fixtures Check if the gauge R&R is done on a yearly basis for all NR ###
Error Proofing (EP) gauges. If gauge R&R is between 10 and 30 percent
(according MSA & PPAP Manual) action plan is required.
Look for EP verification methods.
G
G
Leadership should ensure the Control Plan includes verification of job
CP issues are reviewed at the daily management meeting,
set-ups; first-off/last-off part validation and a reaction plan when non
40
conformity product is detected and to ensure that discrepancies from CP
Daily Meetings including timed with responsibility and documented on Plant NR ###
Informational Board (Fast Response Board).
are managed as priority areas for process improvement. G
Look for shift log/notes/Quality Alert.
Look for evidence of a closed loop on shift problems, ideally
If more than one shift, part problem information is to be passed across person to person cross over.
41
shifts.
Shift Log
Check for up to date information board with training records, I-
NR ###
chart, layered audit plan/results, quality emerging issues / high
focus areas G
The Organization shall review Control Plans, and update as required, for
CP
any of the following: non conformities shipped to costumer, when any Audit frequency, schedule by auditor, report form or checklist.
42
change occurs, after costumer complaint (SPPS), and implementation of
CP Review Meetings Minutes
Management involvement and schedule.
NR ###
SPPS
CA and at a set frequency based on a risk analysis.
G
Supplier Representative Name with Signature Follow-Up Audit Date GM Representative Name with Signature
# 1 2 3 4 5 6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
C16: ACTION ITEM: The item that requires action to improve the process or quality of the product being produced.
D16: 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.
E15: Formula: DO NOT TYPE IN THIS CELL, UNLESS YOUR ARE MODIFYING THE FORMULA
E16: START DATE: The date the action item was identified and listed in the action item column
F16: 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
G15: Formula: DO NOT TYPE IN THIS CELL, UNLESS YOUR ARE MODIFYING THE FORMULA
G16: ACTUAL CLOSE DATE: The date the action item was closed TO INCLUDE VALIDATION.
The SQE should validate the action item as being closed and RESOLVED.
H16: LAST UPDATE: The date the SQE reviewed the action item.
I16: 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
Section Change
Quality System Implementation by Management
BIQS implementation to replace QSB+
Worksheet: Item 57
1.0 8-Jun-16