• Frank Precision Castings 弗兰克精密铸造有限公司
    Continuous Improvement 连续性提高
    Basic Quality Audit Plan 基本质量审核计划
    With the progression of FPC in the manufacturing volumes of Adaptors & Teeth castings for CR it has been identified that the need of an Audit Procedure to allow checks to be carried out during visits to the foundry to ensure that the processes and procedures in place are being carried out as they are documented.
    随着弗兰克铸厂为CR制造的齿座和斗齿数量不断增加,我们认定弗兰克需要一套审核程序,在CR访问铸厂时能使审查顺利进行,因为有相应的文件,所以就可以确保流程和工艺能顺利恰当地执行。

1.Order, MDS & Drawing Control 订单,金属材质表和图纸的管理 - [Audit Frequency 审核频率 = Twice per Year 每年两次] ITP Sign off ITP签字验收 = No

  • Current Date and Time.

  • Department Supervisor Name:

  • 1.1 Who receives CR Purchase Orders from CR/TDES? 谁从CR/TDES收到CR的订单?

  • 1.2 Where are the PO’s registered?订单记录在哪?

  • 1.3 Is the new PO’s reviewed for changes? 新订单有无因改变而复审?

  • 1.4 Who gets a copy of the MDS?谁拿到了金属材质表的复印件?

  • 1.5 Who gets a copy of the Drawing?谁拿到了图纸的复印件?

  • 1.6 Are records maintained relating deliveries on time? 记录是否维持相应的按时交货期?

  • 1.7 What method of reporting production updates is used to CR? 采用哪种方法向CR汇报生产进度更新?

2. Planning生产计划 - [Audit Frequency 审核频率 = Monthly 每个月] ITP Sign off ITP签字验收 = No

  • Current Date and Time.

  • Department Supervisor Name:

  • 2.1 Who sets the Production Plan and maintains and monitors it? 谁制定了生产计划并保证顺利进行和监控?

  • 2.2 How does the Planner get the order & MDS information for the months production?为了每月的生产,制定计划者怎样得到订单信息和金属材质表信息?

  • 2.3 Are there any regular production meetings to reviewing the performance of workshops to the plan?是否有固定的生产会议来检查回顾各个车间在生产计划中的表现?

  • 2.4 Who approves the plan for Production?谁批准了生产计划?

  • 2.5 Who gets a copy of the Plan?谁拿到了生产计划的复印件?

  • 2.6 Are records maintained for all stages of the process for improvements? 记录是否包含了改进过程的所有阶段?

3. Issue Tooling 模具事宜 - [Audit Frequency 审核频率 = Twice per Year 每年两次] ITP Sign off ITP签字验收 = No

  • Current Date and Time.

  • Department Supervisor Name:

  • 3.1 How do you know what Parts to issue to the Moulding Shop? 你是如何知道哪些模具要发往造型车间?

  • 3.2 Is there a current Production Plan in the area & how are the areas achievements reported? 在此区域是否有当前的生产计划,以及获得的成果如何汇报?

  • 3.3 Is there a current drawing available? 是否有当前可用的图纸?

  • 3.4 Is there a current MDS available? 是否有当前可用的金属材质表?

  • 3.5 What checks are carried out before release and is there a sign off? 在模具使用前要执行怎样的检查?是否有验收签字?

  • 3.6 How can the pattern store tell if there is a modification? 模具仓库怎样断定模具是否有修改或要修改?

  • 3.7 How are the core boxes issued to the core making shop? 芯盒要怎样发到制芯车间?

4. Methods & Moulding 造型系统和工艺 - [Audit Frequency 审核频率 = 4 x Yearly 每年四次] ITP Sign off ITP签字验收 = No

  • Current Date and Time.

  • Department Supervisor Name:

  • 4.1 Is there a current Production Plan in the area & how are the areas achievements reported? 在此区域是否有当前的生产计划,以及获得的成果如何汇报?

  • 4.2 With the core manufacture how far ahead are they made? 制芯车间提前多久制芯?

  • 4.3 How are the cores identified to the correct moulds? 如何判定芯子是否与相应的模具配合?

  • 4.4 Is there a current Method available in workshop? 在车间是否有当前可用的造型工艺?

  • 4.5 What checks are carried out before casting and is there a sign off?在浇注前,进行了什么样的检查,是否有签名确认?

  • 4.6 Material Checks & Calibration of equipment? 是否进行了材料检查和仪器校正?

  • 4.7 How are the different heats identified? 不同的炉次如何辨别?

5. Melting & Pouring 熔炼和浇注 - [Audit Frequency 审核频率 = 2 x Yearly 每年四次] ITP Sign off ITP签字验收 = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 5.1 Is there a current Production Plan in the area & how are the areas achievements reported? 在此区域,是否有当前的生产计划,以及获得的成果如何汇报?

  • 5.2 How are the moulds identified for pouring in the correct material grade? 如何从模具上识别浇注的正确材料等级?

  • 5.3 Is there a current MDS available? 是否有当前可用的金属材质表?

  • 5.4 What checks are carried out on the steel scrap & alloys before they are used? 在废钢与合金使用前,要进行什么样的检测?

  • 5.5 Demonstrate how the material specification ins achieved and how the steel sampling process in carried out? 材料规格是如何满足的,取样过程是如何进行的?

  • 5.6 Can any evidence be shown of a completed melt & pour record sheet as per attached Appendix 1a? 有任何证据能展示如附录1a所示的完整的熔炼浇注记录表吗?

  • 5.7 How often are there material samples checked & Calibration of the Spectrometer? 这些材料样块多长时间检查一次,光谱仪多久校正一次?

6. Chemistry 化学成分 - [Audit Frequency 审核频率 = 2 x Yearly 每年四次] ITP Sign off ITP签字验收 = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 6.1 Can any evidence be shown of a completed Chemistry record sheet as per attached Appendix 2a? 有任何证据能表明如附录2a所示一个完整的化学成分记录表吗?

  • 6.2 How are non conforming Chemistries reported to CR? 不合格的化学成分是如何报给CR的?

  • 6.3 Is there a set time frame for reporting and receiving a judgment on non complaint Chemistry reports? 有没有一套固定的时间范围来汇报并接受关于不合格化学成分的判断?

7. Heat Treatment (Homogenise) (Q & T) 热处理(均质化处理)(淬火和回火)- [Audit Frequency 审核频率 = 2 x Yearly 每年四次] ITP Sign off ITP签字验收 = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 7.1 Is there a current Production Plan in the area & how are the areas achievements reported? 在此区域是否有当前的生产计划,这些区域的成果如何汇报?

  • 7.2 How is the product recognised to be ready for a specific heat treatment cycle? 怎样认可产品来准备进行一次特殊的热处理周期?

  • 7.3 Is there a current MDS available? 是否有当前可用的金属材质表?

  • 7.4 Is there a set layout on the heat treatment tray for the different products? 针对不同产品,是否有规定的在热处理托盘上的摆放布局设计?

  • 7.5 Is each of the heat treatment cycles recorded on a chart and part & casting number recoded on it as per Appendix 3a? 是否每次热处理周期都记录在表上,并且零件号和铸件号也如附录3a一样记录在上面?

  • 7.6 Are all castings recorded per heat treatment load on the record sheet as per Appendix 4a? 如每一个附录4a一样,是否每次热处理中的所有铸件都记录在表上?

  • 7.7 Explanation on how test bars are loaded in each heat treatment cycle and recorded? 解释试棒在每次热处理周期中是如何放置并记录的?

  • 7.8 At what stage is the Test blocks cut into test bars? 在什么阶段,会线切割小试块?

  • 7.9 Are castings hardness tested in the area nominated by CR? 是否铸件的硬度测试 在CR确认的区域进行?

8. NDT & Weld (If Applicable) 无损检测和 补焊(如果需要 - [Audit Frequency 审核频率 = 2 x Yearly 每年四次] ITP Sign off ITP签字验收 = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 8.1 Is there a current Production Plan in the area & how are the areas achievements reported? 在此区域,是否有现有的生产计划,在这些区域获得的成果如何汇报?

  • 8.2 Is there a current MDS available? 是否有当前可用的金属材质表?

  • 8.3 Are the CR work instructions for U/T & MPI being used and followed for each of the product groups? 对每一组产品,CR关于超声探伤和磁粉探伤的工作指导是否有采用和遵循?

  • 8.4 What CR specification is used to determine the acceptance criteria for the product? 采用什么样的CR产品规格来决定产品可接受的条件?

  • 8.5 If a nonconforming indication is found by NDT on a casting what procedure is followed? 如果在铸件上由无损检测发现不符合要求的缺陷,应采取什么样的程序?

  • 8.6 Have any welders been approved by CR for Pre and or Post Quench & Temper repair? 是否有任何焊工由CR承认可进行淬火回火之前与之后的补焊?

  • 8.7 Is the welding consumable being used compatible with CR weld procedures? 使用的焊材是否与CR补焊程序相适合?

  • 8.8 If weld repairs are to be carried out are there maps made to record location and size of the repair? 如果要进行补焊,有没有制作示意图来记录补焊的位置与尺寸?

  • 8.9 NDT results are recorded on the sheet as per Appendix 5 a. 无损检测结果记录在如附录5a所示的表上

9. Met Release (Hardness & Mechanical) 放行报告(硬度和机械性能 - [Audit Frequency 审核频率 = 4 x Yearly 每年四次] ITP Sign off ITP签字验收 = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 9.1 Is there a current Production Plan in the area & how are the areas achievements reported? 在此区域是否有现有的生产计划,这些区域取得的成果如何汇报?

  • 9.2 Is there a current MDS available? 是否有当前可用的金属材质表?

  • 9.3 How are the testbars cut into test pieces for impact testing? 为冲击测试,试棒是如何被切为小试块的?

  • 9.4 What CR specification is used to determine the acceptance criteria for the product? 采用 CR产品的什么规格,来决定产品可接受的条件?

  • 9.5 Is the CR work instruction followed for Charpy Impact testing? 在冲击测验中,是否采用了CR的工作程序?

  • 9.6 If a nonconforming result is recorded what procedure is followed? 如果记录了一个不合格的结果,然后要采取什么样的程序?

  • 9.7 Calibration of all equipment up to date? 所有仪器是否为最近矫正的?

  • 9.8 Hardness Testing of all test bars is carried out using what type equipment? 使用何种仪器来测量所有试棒的硬度?

  • 9.9 Mechanical results ,hardness & test bar Chemical results are recorded on the sheet as per Appendix 6 a. 机械性能结果,硬度和试棒化学成分要记录在如附录6a的表上。

10. Fit & Gauge 打磨与过检具 - [Audit Frequency 审核频率 = 4 x Yearly 每年四次] ITP Sign off ITP签字验收 = No

  • Select date

  • Department Supervisor Name:

  • 10.1 Who manages the gauges in the Store? 在仓库中,谁管理检具?

  • 10.2 Is there a current MDS available? 是否有当前可用的金属材质表?

  • 10.3 Are the CR work instructions for Gauging being used and followed for each of the product groups? 对每一组产品,是否采用并遵循了CR对检具的工作指导?

  • 10.4 Is there a final inspection carried out by the Foundry before CR\TDES do a release inspection. 在CR/TDES做放行检测前,铸厂是否会对铸件进行终检。

  • 10.5 If a nonconforming fit is found by final or CR\TDES inspection in a gauged area what procedure is followed? 如果由铸厂终检或CR/TDES的检测在过检具区域发现了不合格的打磨,应采取什么样的程序?

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