Ambitermo Audit Process- Welding

Audit Process- Welding (Supply Chain).

• Document No.

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Comments/ Recommendations:

Supplier Information and Review.

• Company Name

• Add location
  Address

• When was the Company Established.

• What is the the Business Characterization.

• What is the Size of the Facility?.

• Shift Length (hrs).

• How many Employees.

• No. of Weld Inspectors

• Are there any QA/QC Personnel on Staff

  Yes

  No

  N/A

• Is there a Certified Weld Inspector on Site?.

  Yes

  No

  N/A

• Is DCMA on Site?.

  Yes

  No

  N/A

• Is there ASNT Level I/II/III NDT Inspectors.

  Yes

  No

  N/A

• Are there any NAS- 410 NDT Inspectors on Staff?.

  Yes

  No

  N/A

• Does the Company Employ and Document any NDT Methods

  Yes

  No

  N/A

• Does the Company have Certified Welders on Staff

  Yes

  No

  N/A

• Does the Company have any Weld Supervisor's on Staff.

  Yes

  No

  N/A

• Does the Company have any Weld Engineers on Staff.

  Yes

  No

  N/A

• Does the Company have any MFG Engineers on Staff.

  Yes

  No

  N/A

• Does the Supplier presently do work for the Client?.

  Yes

  No

  N/A

• Quality Systems Approvals

  Yes

  No

  N/A

• Is there Separation in Reporting Duties for personnel responsible for Quality.

  Yes

  No

  N/A

• Does the Quality Control Inspector have the Authority to "Stop Work", the responsibility to Identify Quality Problems and Provide Recommendations.

  Yes

  No

  N/A

• Is there Objective Evidence of a Review Process of Certified Material Test Reports (CMTR) to ASTM Specifications. Note: If CMTR are not required to be kept of file per Contract Documents. the fabricator shall still show the capability of Reviewing the Reports.

  Yes

  No

  N/A

• Are materials identified and traceable as specified in the Technical Data Package (TDP). (Quality Program Receiving and Manufacturing Operations).

  Yes

  No

  N/A

• Do Purchase Orders for filler material specify the American Welding Society (AWS) Classification and Specification?.

  Yes

  No

  N/A

• Comments/ Recommendations:

Reference Library- All Reference Material Shall be to the Latest Published Version or Revision.

• Does the Supplier have the Document "Aluminum Design Manual" from the Aluminum Association on File.

  Yes

  No

  N/A

• AMS-STD- 1595 (Qualification of Aircraft, Missile & Aerospace Fusion Welders) on File.

  Yes

  No

  N/A

• ANSI Z49.1 (Safety in Welding, Cutting and Allied Processes)

  Yes

  No

  N/A

• Boiler and Pressure Vessel Code, Section V: Nondestructive Examination.

  Yes

  No

  N/A

• What (Standard Practice for Magnetic Particle Testing)

  Yes

  No

  N/A

• What (Standard Practice for Liquid Penetrant Testing)

  Yes

  No

  N/A

• What (Standard Practice for Radiographic Examination)

  Yes

  No

  N/A

• What (Standard Practice for Liquid UltrasonicTesting)

  Yes

  No

  N/A

• What (Standard Reference Radiographs for Examination of Aluminum Fusion Welds)

  Yes

  No

  N/A

• What (Guide for the Visual Examination of Welds)

  Yes

  No

  N/A

• What (Standard Welding terms and Definitions)

  Yes

  No

  N/A

• What ( Specification for Welding Procedure and Performance Qualification).

  Yes

  No

  N/A

• What (Standard Methods for Mechanical Testing of Welds)

  Yes

  No

  N/A

• What (Structural Welding Code- Steel)

  Yes

  No

  N/A

• What (Structural Welding Code- Aluminum)

  Yes

  No

  N/A

• What (Structural Welding Code- Sheet Steel)

  Yes

  No

  N/A

• What(Structural Welding Code- Stainless Steel)

  Yes

  No

  N/A

• What (Structural Welding Code- Titanium)

  Yes

  No

  N/A

• What (Sheet Metal Welding Code)

  Yes

  No

  N/A

• What (Specification for Fusion Welding for Aerospace Application)

  Yes

  No

  N/A

• What (Specification for Resistance Welding for Aerospace Application)

  Yes

  No

  N/A

• What (Standard Symbols for Welding, Brazing and Nondestructive Examination)

  Yes

  No

  N/A

• What spec (Fusion Welding for Aerospace Application)

  Yes

  No

  N/A

• What spec (Requirements for Nondestructive Testing Methods)

  Yes

  No

  N/A

• What spec (Nondestructive Testing Acceptance Criteria)

  Yes

  No

  N/A

• What spec (Welding, Resistance: Spot and Seam)

  Yes

  No

  N/A

• NADCAP welding documents (e.g., SAE AS 7110, NADCAP Requirements for Welding/Brazing)

  Yes

  No

  N/A

• NADCAP NDT Inspection Documents

  Yes

  No

  N/A

• NAVSEA Welding Standard 250-1500-1

  Yes

  No

  N/A

• NAVSEA Technical Publication S9074-AQ-GIB-010/248

  Yes

  No

  N/A

• NAVSEA Technical Publication S9074-AR-GIB-010/278

  Yes

  No

  N/A

• NAS-410 (Certification & Qualification of Nondestructive Test Personnel)

  Yes

  No

  N/A

• WS 33739 (Raytheon Process Specification for Aerospace Fusion Welding)

  Yes

  No

  N/A

Certifications to:

• Visual Inspection (VT)

  Yes

  No

  N/A

• Radiographic Inspection (RT)

  Yes

  No

  N/A

• Ultrasonic Inspection (UT)

  Yes

  No

  N/A

• Magnetic Particle (MT)

  Yes

  No

  N/A

• Dye Penetrant Inspection (PT)

  Yes

  No

  N/A

Qualifications to:

• ASTM E164

  Yes

  No

  N/A

• ASTM E1417

  Yes

  No

  N/A

• ASTM E1444

  Yes

  No

  N/A

• ASTM E1742

  Yes

  No

  N/A

• AWS QC1

  Yes

  No

  N/A

Health and Safety

• Is there an EH&S (Environmental Health & Safety) Officer or an Industrial Hygienist on Site?.

  Yes

  No

  N/A

• Does the company have a written Health and Safety Policy Statement

  Yes

  No

  N/A

• Does the policy commit to continual improvement and accident reduction/maintaining a safe workplace for its employees/contractors

  Yes

  No

  N/A

• Is the policy reviewed on a annual basis and signed by the managing director

  Yes

  No

  N/A

• Has the organisation a designated Health and Safety professional or use the service of a Health and Safety consultancy for advice/information

  Yes

  No

  N/A

• Does the organisation have a Health and Safety organisation chart/mechanism that specify the responsibilities of all staff with regards to Health and Safety

  Yes

  No

  N/A

• Does the organisation have a Health and Safety Risk Register to identify hazards to staff or another arrangement to identify hazards

  Yes

  No

  N/A

• Does the organisation carry out risk and COSHH assessments identified in the hazard register specific to the task or use generic assessments

  Yes

  No

  N/A

• Does the organisation produce method statements in conjunction with the risk assessment process and publicise these to staff affected by the work (Construction Site Work)

  Yes

  No

  N/A

• Does the organisation employ young persons <18 yrs and carry out suitable and sufficient risk assessment

  Yes

  No

  N/A

• Does the organisation maintain a legislative register of all applicable Health and Safety legislation and review it regularly

  Yes

  No

  N/A

• Does the organisation maintain registers for assets that require mandatory testing e.g Portable Appliance Testing, Lifting Equipment, Pressure Systems and Local Exhaust Ventilation

  Yes

  No

  N/A

• Does the organisation carry out induction training for all new staff and induction to construction sites (if applicable)

  Yes

  No

  N/A

• Does the organisation carry out In-house Health and Safety training for issues like Manual Handling, COSHH, Fire Wardens and Personal Protective Equipment

  Yes

  No

  N/A

• Does the organisation have and maintain a Health and Safety Training Matrix for all staff

  Yes

  No

  N/A

• Does the organisation have Emergency Action Plan/Procedures in place for accidents/emergencies and carry out drills practices of them

  Yes

  No

  N/A

• Does the organisation have arrangements in place to communicate with its employees and/or subcontractors on Health and Safety issues and are records maintained

  Yes

  No

  N/A

• Does the organisation carry out and report on accidents, incidents and near misses in a timely manner and communicate them to their workforce

  Yes

  No

  N/A

• Is there objective evidence of a Welding Safety Program?

  Yes

  No

  N/A

• Is there objective evidence of Safety Training classes being conducted.

  Yes

  No

  N/A

• Is the facility environmentally controlled (i.e., fully heated and/ or air conditioned)

  Yes

  No

  N/A

• Is the relative humidity monitored and documented within the facility or the Welding Environment

  Yes

  No

  N/A

• Does the facility have a welding gas distribution system?.

  Yes

  No

  N/A

• Are the Oxygen levels Monitored?.

  Yes

  No

  N/A

• Is there a facility Equipment List/ Capabilities Profile sheet available?.

  Yes

  No

  N/A

• Does the facility have lifting crane capacity within the welding area?

  Yes

  No

  N/A

• What type of lifting crane?.

  Yes

  No

  N/A

• Does the facility employ welding positioners.

  Yes

  No

  N/A

• Is there a designated area for weld and/or Base Material grinding?.

  Yes

  No

  N/A

• Is the Welding / Fabrication Area Safe, Clean and Orderly.

  Yes

  No

  N/A

• Are there Welding Fume Extractors

  Yes

  No

  N/A

• Are Pre and Post Weld heat treatments (PWHT) performed at the Facility

  Yes

  No

  N/A

• Are there Separate Work Areas for Stainless Steel, Titanium, CArbon Steel or Aluminum

  Yes

  No

  N/A

• Is Blast cleaning performed at the Facility

  Yes

  No

  N/A

• Is Base material or Weld metal Analyzed

  Yes

  No

  N/A

• Laboratory Info.

  Yes

  No

  N/A

• Does the organization perform leak testing

  Yes

  No

  N/A

• What Type of Process?.

  Yes

  No

  N/A

• Is there objective evidence of weld operator annual vision test

  Yes

  No

  N/A

• Is there objective evidence of weld inspector's annual vision test

  Yes

  No

  N/A

• Comments/ Recommendations

Quality Control- Documentation

• Does the Organization have a Quality and Procedures Manual

  Yes

  No

  N/A

• Does the organisation have a written quality policy statement.

  Yes

  No

  N/A

• Is the management system manual reviewed and up to date

  Yes

  No

  N/A

• Contract review. Are client requirements, industry standards and legislation acknowledged

  Yes

  No

  N/A

• Design Control-are drawings, data sheets, specifications, check/approved, are design documents from suppliers checked<br><br>Are the overall finalised design documents verified by a meeting

  Yes

  No

  N/A

• Is the Document Control managed by a authorisation level, standard numbering system, version control & standard filing location

  Yes

  No

  N/A

• Is Production Control managed by planning, materials traceability and suitable infrastructure. <br><br>If so, are the materials checked against the required specifications and client requirements

  Yes

  No

  N/A

• Purchasing and Supplier Evaluation. Are purchasing documents checked and is there proactive vendor management

  Yes

  No

  N/A

• Inspection, Test and Calibration Records. Gauges, Instruments subject to calibration? Are there, works inspection/quality plan records, goods incoming (material Certs) and records

  Yes

  No

  N/A

• Are customer Complaints analysed, acknowledged and actions implemented?

  Yes

  No

  N/A

• Is there control of Non-conforming product through containment and trend and root cause analysis

  Yes

  No

  N/A

• To enable Continuous Improvement and measure objectives, is data analysed from audits, inspections records, customer feedback and non conformance

  Yes

  No

  N/A

• Are customer satisfaction surveys carried out

  Yes

  No

  N/A

• Are Internal Audits conducted, findings analysed and actions closed out

  Yes

  No

  N/A

• Are Sub-Tier Suppliers Qualified by a documented evaluation?.

  Yes

  No

  N/A

• Do purchase orders for base material (Nuts, washers, Bolts, Bar Stock etc specify the Grade?.

  Yes

  No

  N/A

• Is the base material currently being used on the shop floor traceable to a Certified Mill Test Report (CMTR)

  Yes

  No

  N/A

• Do purchase orders for filler material specify the American Welding Society (AWS) classification and specification.

  Yes

  No

  N/A

• Is the filler material currently being used on the shop floor traceable to a Certified Mill Test Report (CMTR)

  Yes

  No

  N/A

• Do purchase orders for Paint specify it's Requirements

  Yes

  No

  N/A

• Is the paint currently being used on the shop floor traceable to a Test Report (CMTR)

  Yes

  No

  N/A

• Have controls been established to monitor the receipt of incoming Material.

  Yes

  No

  N/A

• Is a quality control program in effect to allow management to assess whether work is being performed according to specification?.

  Yes

  No

  N/A

• Is there objective evidence of correction of non-conforming material or work in process

  Yes

  No

  N/A

• Are weldments traceable to a Qualified or Certified Welder

  Yes

  No

  N/A

• Is the objective evidence that a welder/ weld operator has worked with a particulate process, material type and weld joint geometry within the last 6 months

  Yes

  No

  N/A

• Is there a formal Material Review Board (MRB) process established to disposition weld defects?.

  Yes

  No

  N/A

• Is there objective evidence to assure that welds are not obstructed by subsequent operations and are inspected prior to being covered up (e.g. witness/ inspection hold points on traveller).

  Yes

  No

  N/A

• Are Requests for Information (RFI's) necessary to resolve discrepancies and variations from contract requirements documented?.

  Yes

  No

  N/A

• Is there a procedure for processing revised or voided drawings

  Yes

  No

  N/A

Quality Control- Welding Consumables

• Are sub-merged arc welding (SAW) fluxes and filler wire properly identified?.

  Yes

  No

  N/A

• Is the Filler wire and Flux stored in a secure, clean and dry environment?,

  Yes

  No

  N/A

• Are Flux and Filler materials stored per manufactures recommendations?.

  Yes

  No

  N/A

• Are there established procedures for the proper storage and control of low hydrogen Shielded Metal Arc Welding (SMAW) electrodes.

  Yes

  No

  N/A

• When Low hydrogen filler metal is used from an Oven is the environment with in the storage oven measured?.

  Yes

  No

  N/A

• Are welding filler metal traceable to a Certified Mill Test Report (CMTR)

  Yes

  No

  N/A

• Are the welding consumables Heat No. And Lot No. documented on the Traveler/ Router (If required by the contract specifications)

  Yes

  No

  N/A

• Do the Welding Consumables meet the Contract Specifications?.

  Yes

  No

  N/A

• Is weld filler wire distribution Controlled?.

  Yes

  No

  N/A

• Are used weld filler wire disposed of After welding activities (e.g. Stub-end Box),

  Yes

  No

  N/A

• Is the welding filler wire sent to an independent Material's Lab for Testing and P.O. verification prior to being employed.

  Yes

  No

  N/A

• If the Organization mixes their own shielding gases are Calibrated Mixture Chambers used?.

  Yes

  No

  N/A

Procedure Qualification Records (PQR's) and Welding Procedure Specifications (WPS's) are qualified in accordance with what Code:

• AWS B2.1

  Yes

  No

  N/A

• AWS D1.1

  Yes

  No

  N/A

• AWS D1.2

  Yes

  No

  N/A

• AWS D1.3

  Yes

  No

  N/A

• AWS D1.6

  Yes

  No

  N/A

• AWS D9.1

  Yes

  No

  N/A

• AWS D17.1

  Yes

  No

  N/A

• AWS D17.2

  Yes

  No

  N/A

• ASME IX

  Yes

  No

  N/A

• NAVSEA

  Yes

  No

  N/A

• MIL-W-6858

  Yes

  No

  N/A

What position(s) are Welders qualified in:

• Groove Welds:

  Yes

  No

  N/A

• 1G

  Yes

  No

  N/A

• 2G

  Yes

  No

  N/A

• 3G

  Yes

  No

  N/A

• 4G

  Yes

  No

  N/A

• 5G

  Yes

  No

  N/A

• 6G

  Yes

  No

  N/A

• 6GR

  Yes

  No

  N/A

• Fillet Welds:

  Yes

  No

  N/A

• 1F

  Yes

  No

  N/A

• 2F

  Yes

  No

  N/A

• 3F

  Yes

  No

  N/A

• 4F

  Yes

  No

  N/A

• 5F

  Yes

  No

  N/A

• 6F

  Yes

  No

  N/A

• Has the Organization engaged in DOD/ Military (MIL-STD) welding activities prior to this audit?.

  Yes

  No

  N/A

• What is the percentage of Military Welding Activities?.

Quality Control- Welding Operations

• Does the Organization utilize Weld Chambers?.

  Yes

  No

  N/A

• Are O2 Analyzers Installed?.

  Yes

  No

  N/A

• Are O2 Levels verified within a purge gas/ Weldment environment?.

  Yes

  No

  N/A

• Are Pre-Weld, Inter-pass and Post-Weld Cleaning Requirements defined to the Welding Procedure Specification (WPS)

  Yes

  No

  N/A

• Is there objective evidence that surface condition and cleanliness of the weld joint fraying surfaces and filler metal has been examined prior to welding?.

  Yes

  No

  N/A

• Are Preheat, Inter-pass and Post-Weld heat treatment addressed on the Welding Procedure Specification (WPS)

  Yes

  No

  N/A

• Surface contacting Pyrometer

  Yes

  No

  N/A

• Temperature Crayons

  Yes

  No

  N/A

• Liquid

  Yes

  No

  N/A

• Pellets

  Yes

  No

  N/A

• Stickers

  Yes

  No

  N/A

• IR heat sensor

  Yes

  No

  N/A

• For automatic/ mechanized welding (as defined in AWS A3.0), are the weld settings used in production within range of those documented on the WPS or PQR?.

  Yes

  No

  N/A

• Is there an established Calibration Program for the calibration of Welding Supplies, Panel Ammeters, Panel Voltmeters, Wire Feeders, Positioners etc.

  Yes

  No

  N/A

• For semi-automatic welding (as defined in AWS A3.0), are the weld settings used in production within range of those documented on the WPS or PQR?.

  Yes

  No

  N/A

• Is there an established Calibration Program for the calibration of Welding Supplies, Panel Ammeters, Panel Voltmeters, Wire Feeders, Positioners etc.

  Yes

  No

  N/A

Quality Control- Weld Inspection.

• Are weld inspectors qualified and knowledgeable with the Specifications, which apply to the Fabricators work

  Yes

  No

  N/A

• Are written welding procedures in close proximity to and used by the Welders

  Yes

  No

  N/A

• Are tools or aids used for visual weld inspection.

  Yes

  No

  N/A

• Fillet Weld Gage's

  Yes

  No

  N/A

• Borescopes

  Yes

  No

  N/A

• Fiberscopes

  Yes

  No

  N/A

• Videoscopes

  Yes

  No

  N/A

• Are there Hold Points at the facility strictly devoted to weld inspection?.

  Yes

  No

  N/A

• Is there objective evidence of Visual (VT) weld inspection being performed Before, During and After additional Stress inducing Operations (e.g. straightening or heat-treating)

  Yes

  No

  N/A

• Is there a formal Material Review Board (MRB) established for disposition of non-conforming weldments.

  Yes

  No

  N/A

Environmental Management

• Does the organisation have a written environmental policy statement

  Yes

  No

  N/A

• Does the organisation have a formal environmental management system? If yes please indicate whether it is in accordance with a recognised standard (ISO14001: BS8555' EMAS) and provide a index of the plan and a copy of the certificate

  Yes

  No

  N/A

• Give the name, qualification and specific responsibilities of the person at your organisation for the purpose of environmental performance

  Yes

  No

  N/A

• How does your organisation keep abreast of changes in environmental legislative requirements

  Yes

  No

  N/A

• How is continual improvement in your environmental performance achieved

  Yes

  No

  N/A

• Have you undertaken an environmental review of environmental risk assessment for the organisation? If so please attach a copy

  Yes

  No

  N/A

• How do you assess the environmental competence and consequential training needs for individuals at each level within your organisation. Please state

  Yes

  No

  N/A

• Do you use subcontractors? If so.how do you assess the competency of the subcontractors to discharge their duty of care and obligations of your clients requirements

  Yes

  No

  N/A

• In the last three years has your organisation been prosecuted for environmental offences or had an enforcement order served by an environmental/government agency. Or are there any outstanding orders

  Yes

  No

  N/A

• Does your organisation undertake audits and reviews of environmental performance

  Yes

  No

  N/A

• Does the organisation perform a management review of your systems? How often does this happens? How are outcomes communicated to the company

  Yes

  No

  N/A