Coating Gap Analysis

• Document No.

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

Identify appropriate personnel

• Identify coating specialist dedicated to maintain the coating processes

  100%

  80%

  60%

  40%

  20%

• Identify all coatings operators

  100%

  80%

  60%

  40%

  20%

• Demonstrate qualification record of all identified coatings operators

  100%

  80%

  60%

  40%

  20%

• Identify the maintenance engineer who owns equipment maintenance. Plan, schedule, and record of equipment installation and maintenance

  100%

  80%

  60%

  40%

  20%

• Identify maintenance operators who perform equipment maintenance, i.e. conduct installation and maintenance per defined plan and schedule

  100%

  80%

  60%

  40%

  20%

• Identify coating engineer dedicated to control, qualification, and implementation of coatings processes (cannot be cell leader)

  100%

  80%

  60%

  40%

  20%

• Demonstrate proper certificate and qualification of maintenance operators

  100%

  80%

  60%

  40%

  20%

• Identify all met lab technicians

  100%

  80%

  60%

  40%

  20%

• Demonstrate qualification record of all met lab technicians

  100%

  80%

  60%

  40%

  20%

Audit of qualification status

• List all coatings applied on every component in each coating cell and their corresponding SQ numbers in eSMS

  100%

  80%

  60%

  40%

  20%

• verify all operation steps defined in MPP is included in the standard plan in use

  100%

  80%

  60%

  40%

  20%

• Verify the existence of proper approved work instructions for each coating related operation steps (pre-coating preparation, grit blasting, coating sell set up, coating application, post coating operation, heat treatment and final inspections)

  100%

  80%

  60%

  40%

  20%

• Verify the work instructions in use have appropriate approval and is the same as those documented in eSMS. Pay special attention to the work instructions containing acceptance limits to ensure the limits are consistent with REI, specification or drawing requirements.

  100%

  80%

  60%

  40%

  20%

• Verify the Met lab is qualified and its corresponding SQ number in eSMS

  100%

  80%

  60%

  40%

  20%

• Verify the existence of proper approved work instructions for met lab sample preparation and evaluation

  100%

  80%

  60%

  40%

  20%

• Verify the work instructions in use have appropriate approval and is the same as those documented in eSMS

  100%

  80%

  60%

  40%

  20%

Audit of coatings engineer

• Does the coating engineer have access to required engineering tools and database (PLM, REI, QCR)

  100%

  80%

  60%

  40%

  20%

• Does the coating engineer have access to all of the specifications referenced in the MPP's

  100%

  80%

  60%

  40%

  20%

• Can the coatings engineer identify the appropriate component repair engineer and coating repair engineer for each component the shop repairs

  100%

  80%

  60%

  40%

  20%

• Is there a procedure to train and qualify coatings operator, including meeting all EHS requirements (PPE, safely starting and shutting down equipment, ETC)

  100%

  80%

  60%

  40%

  20%

• Is there a procedure to train and qualify met lab technicians

  100%

  80%

  60%

  40%

  20%

• Verified that all powders used in production are qualified for corresponding application and the information is documented in eSMS

  100%

  80%

  60%

  40%

  20%

• Is there a method of storing and/or tracking furnace run data for each production batch

  100%

  80%

  60%

  40%

  20%

• What is the process that verifies parts leaving the building have passed all required inspections and/or quality checks including metallurgical evaluation of quality audit samples

  100%

  80%

  60%

  40%

  20%

• Is there a process in place for dealing with failure of quality audit samples

  100%

  80%

  60%

  40%

  20%

• Provide information and results of quality audit samples for the previous three months

  100%

  80%

  60%

  40%

  20%

• Is there a log sheet for storing and tracking all defects that occurred in a coating related operations step

  100%

  80%

  60%

  40%

  20%

• Is there a system to track the performance of coating cells (throughput, capacity utilization rate, first time yield, top issues for rework)

  100%

  80%

  60%

  40%

  20%

Audit of operators for coating related operations

• Does the operator have access to approved work instructions related to his or her work

  100%

  80%

  60%

  40%

  20%

• For each coaching related operation steps, can the operator walk the auditor through his or her designated process and detail selection of appropriate tools, fixtures, and programs necessary to complete their task

  100%

  80%

  60%

  40%

  20%

• For each coating related operation steps, can the operator identify tools and fixtures that need to be repaired and replaced

  100%

  80%

  60%

  40%

  20%

• For each coating related operation steps, does the operator perform his or her job according to the procedure defined in the corresponding approved work instructions

  100%

  80%

  60%

  40%

  20%

• For each coating related operation steps, does the operator have a visual tool that describes good and bad conditions for both input and output

  100%

  80%

  60%

  40%

  20%

• After the parts are coated, are the parts well protected against handling and transportation damage

  100%

  80%

  60%

  40%

  20%

• For operations steps involving visual and thickness inspection on parts, does the operator know the inspection criteria defined in approved work instructions

  100%

  80%

  60%

  40%

  20%

• For operation steps involving visual and thickness inspection on parts, is there a process for the operator to track and notify his or her supervisor on quality deviations

  100%

  80%

  60%

  40%

  20%

• For Mach bloc curing, is the part temperature and holding time consistent with what is defined in approved work instructions (if applicable)

  100%

  80%

  60%

  40%

  20%

• For grit blasting, can the operator identify conditions for blasting media and nozzle replacement

  100%

  80%

  60%

  40%

  20%

• For auto grit blasting, can the operator verify the blasting nozzle arrangement and orientation is consistent with what is defined in approved work instructions (if applicable)

  100%

  80%

  60%

  40%

  20%

• During coating, can the operator identify conditions that the process needs to be stopped for troubleshooting and maintenance

  100%

  80%

  60%

  40%

  20%

• During coating, does the operator know when and how to generate quality audit samples

  100%

  80%

  60%

  40%

  20%

• During coating, does each cell have a log sheet or similar system that tracks parts sprayed by serial number, date and time, powder lot, parameters as read from machines, number of passes when the past count is not frozen, weight gain, quality audit sample generation and any special observations

  100%

  80%

  60%

  40%

  20%

• Verify that there are no used items located around the cells that may be confused with new items or reused in the absence of new items

  100%

  80%

  60%

  40%

  20%

• Are all of the coating related operation steps signed off by operators on the standard plan

  100%

  80%

  60%

  40%

  20%

• Is there a log sheet or similar system for storing and tracking all required inspection data collected in coating related operation steps

  100%

  80%

  60%

  40%

  20%

• Provide log sheet of each coating cell for the previous three months

  100%

  80%

  60%

  40%

  20%

• For TBC polishing, does the operator know the pre-polishing coating thickness and required post-polishing coating thickness (if applicable)

  100%

  80%

  60%

  40%

  20%

• Do the coating operators and maintenance operators understand each other's roles and responsibilities regarding to coating related equipment maintenance

  100%

  80%

  60%

  40%

  20%

• Before the parts leave the coating cell, is there a process that the operator can notify his or her supervisor on any parts with quality deviations and keep track of that

  100%

  80%

  60%

  40%

  20%

• Is there a list of maintenance items the operator is expected to perform at the beginning of each shift

  100%

  80%

  60%

  40%

  20%

• Is there a list of maintenance items the operator is expected to perform for all equipment related to coating operations on a weekly, monthly, quarterly, or annual basis (grit blaster, plasma gun, plasma controller, HVOF gun, HVOF controller, powder feeder, exhaust system, water cooling system, gas supply system, robot & turntable)

  100%

  80%

  60%

  40%

  20%

• Is there a system that tracks the history of maintenance and upcoming maintenance items for all equipment related to coating operations

  100%

  80%

  60%

  40%

  20%

• Is there a system/method for the operator to track the issues found and the maintenance performed (including both preventative maintenance and maintenance on broken down equipment)

  100%

  80%

  60%

  40%

  20%

• Provide maintenance record of each coating related equipment for the previous 3 months (including both preventative maintenance and maintenance on broken down equipment)

  100%

  80%

  60%

  40%

  20%

Audit of maintenance engineer

• Is there a system that tracks cell up time and down time

  100%

  80%

  60%

  40%

  20%

• Is there a system that tracks issues that lead to down time and the corresponding corrective action

  100%

  80%

  60%

  40%

  20%

• Is there a list of spare parts and consumables kept in the service center

  100%

  80%

  60%

  40%

  20%

• Is there a minimum requirement by volume of parts and consumables kept in the service center

  100%

  80%

  60%

  40%

  20%

• Is there a system in place that requires ordering of new parts and consumables when items drop below minimum required volume

  100%

  80%

  60%

  40%

  20%

• Is there a disposal system in place for used items exiting the coating cells (powder disposal, parts recycling, etc.)

  100%

  80%

  60%

  40%

  20%

• Is all equipment in the cells serialized for maintenance and cell usage tracking

  100%

  80%

  60%

  40%

  20%

• Does each cell have a log sheet or similar system detailing parts/components changed in the cell

  100%

  80%

  60%

  40%

  20%

• Is that log available for the next shift as a changeover update

  100%

  80%

  60%

  40%

  20%

Audit of maintenance operators

• Do the maintenance operators and coating operators understand each other's roles and responsibilities regarding to coating related equipment maintenance

  100%

  80%

  60%

  40%

  20%

• Do all maintenance operators have access to schematics, diagrams, and user manuals for all equipment related to coatings operations

  100%

  80%

  60%

  40%

  20%

• Is there a list of maintenance items the maintenance operator is expected to perform for all equipment related to coating operations on a weekly, monthly, quarterly, or annual basis (grit blaster, plasma gun, plasma controller, HVOF gun, HVOF controller, powder feeder, exhaust system, water cooling system, gas supply system, robot & turntable)

  100%

  80%

  60%

  40%

  20%

• Is there a system that tracks the history of maintenance and upcoming maintenance items for all equipment related to coating operations

  100%

  80%

  60%

  40%

  20%

• Provide maintenance record of each coating related equipment for the previous 3 months (including both preventative maintenance and maintenance on broken down equipment)

  100%

  80%

  60%

  40%

  20%