Information

Audit Process- Welding (Supply Chain).

  • Document No.

  • Audit Title

  • Client / Site

  • Conducted on

  • Prepared by

  • Comments/ Recommendations:

Supplier Information and Review.

  • Company Name

  • Add location
  • 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

  • Is there a Certified Weld Inspector on Site?.

  • Is DCMA on Site?.

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

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

  • Does the Company Employ and Document any NDT Methods

  • Does the Company have Certified Welders on Staff

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

  • Does the Company have any Weld Engineers on Staff.

  • Does the Company have any MFG Engineers on Staff.

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

  • Quality Systems Approvals

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

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

  • 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.

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

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

  • 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.

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

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

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

  • ASTM E 1444 (Standard Practice for Magnetic Particle Testing)

  • ASTM E1417 (Standard Practice for Liquid Penetrant Testing)

  • ASTM E1742 (Standard Practice for Radiographic Examination)

  • ASTM E164 (Standard Practice for Liquid UltrasonicTesting)

  • ASTM E1648 (Standard Reference Radiographs for Examination of Aluminum Fusion Welds)

  • AWS B1.11 (Guide for the Visual Examination of Welds)

  • AWS A3.0 (Standard Welding terms and Definitions)

  • AWS B2.1 ( Specification for Welding Procedure and Performance Qualification).

  • AWS B4.0 (Standard Methods for Mechanical Testing of Welds)

  • AWS D1.1 (Structural Welding Code- Steel)

  • AWS D1.2 (Structural Welding Code- Aluminum)

  • AWS D1.3 (Structural Welding Code- Sheet Steel)

  • AWS D1.6 (Structural Welding Code- Stainless Steel)

  • AWS D1.9 (Structural Welding Code- Titanium)

  • AWS D9.1 (Sheet Metal Welding Code)

  • AWS D17.1 (Specification for Fusion Welding for Aerospace Application)

  • AWS D17.2 (Specification for Resistance Welding for Aerospace Application)

  • AWS A2.4 (Standard Symbols for Welding, Brazing and Nondestructive Examination)

  • MIL-STD-2219 (Fusion Welding for Aerospace Application)

  • MIL-STD-271 (Requirements for Nondestructive Testing Methods)

  • MIL-STD-2035 (Nondestructive Testing Acceptance Criteria)

  • MIL-W-6858 (Welding, Resistance: Spot and Seam)

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

  • NADCAP NDT Inspection Documents

  • NAVSEA Welding Standard 250-1500-1

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

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

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

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

Certifications to:

  • Visual Inspection (VT)

  • Radiographic Inspection (RT)

  • Ultrasonic Inspection (UT)

  • Magnetic Particle (MT)

  • Dye Penetrant Inspection (PT)

Qualifications to:

  • ASTM E164

  • ASTM E1417

  • ASTM E1444

  • ASTM E1742

  • AWS QC1

Health and Safety

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

  • Is there objective evidence of a Welding Safety Program?

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

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

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

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

  • Are the Oxygen levels Monitored?.

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

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

  • What type of lifting crane?.

  • Does the facility employ welding positioners.

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

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

  • Are there Welding Fume Extractors

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

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

  • Is Blast cleaning performed at the Facility

  • Is Base material or Weld metal Analyzed

  • Laboratory Info.

  • Does the organization perform leak testing

  • What Type of Process?.

  • Is there objective evidence of weld operator annual vision test

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

  • Comments/ Recommendations

Quality Control- Documentation

  • Does the Organization have a Quality and Procedures Manual

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

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

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

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

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

  • Do purchase orders for Paint specify it's Requirements

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

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

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

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

  • Are weldments traceable to a Qualified or Certified Welder

  • 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

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

  • 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).

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

  • Is there a procedure for processing revised or voided drawings

Quality Control- Welding Consumables

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

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

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

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

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

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

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

  • Do the Welding Consumables meet the Contract Specifications?.

  • Is weld filler wire distribution Controlled?.

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

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

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

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

  • AWS B2.1

  • AWS D1.1

  • AWS D1.2

  • AWS D1.3

  • AWS D1.6

  • AWS D9.1

  • AWS D17.1

  • AWS D17.2

  • ASME IX

  • NAVSEA

  • MIL-W-6858

What position(s) are Welders qualified in:

  • Groove Welds:

  • 1G

  • 2G

  • 3G

  • 4G

  • 5G

  • 6G

  • 6GR

  • Fillet Welds:

  • 1F

  • 2F

  • 3F

  • 4F

  • 5F

  • 6F

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

  • What is the percentage of Military Welding Activities?.

Quality Control- Welding Operations

  • Does the Organization utilize Weld Chambers?.

  • Are O2 Analyzers Installed?.

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

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

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

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

  • Surface contacting Pyrometer

  • Temperature Crayons

  • Liquid

  • Pellets

  • Stickers

  • IR heat sensor

  • 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?.

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

  • 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?.

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

Quality Control- Weld Inspection.

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

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

  • Are tools or aids used for visual weld inspection.

  • Fillet Weld Gage's

  • Borescopes

  • Fiberscopes

  • Videoscopes

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

  • 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)

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

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