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

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• ASTM E1417 (Standard Practice for Liquid Penetrant Testing)

  Yes

  No

  N/A

• ASTM E1742 (Standard Practice for Radiographic Examination)

  Yes

  No

  N/A

• ASTM E164 (Standard Practice for Liquid UltrasonicTesting)

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• AWS D9.1 (Sheet Metal Welding Code)

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• MIL-W-6858 (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

• 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

• 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