• Yingliu
    Continual Improvement
    Basic Quality Audit Plan

    With the progression of Yingliu in the manufacturing of HEX lips 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.

1. Order, MDS & Drawing Control - [Minimum Audit Frequency = 2 X per Year] - ITP Sign Off = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 1.1 Who receives CR Purchase Orders from CR/TDES?

  • 1.2 Are the PO's registered?

  • 1.3 Is the new PO's, MDS & Drawings reviewed for changes?

  • 1.4 Who gets a copy of the MDS ? & If a new revision is supplied how is this new copy controlled?

  • 1.5 Who gets a copy of the Drawing ? & If a new revision is supplied how is this new copy controlled?

  • 1.6 Are records maintained relating to achieving deliveries on time?

  • 1.7 What method of reporting production updates is used for CR ? e.g. Tracking sheet and who is responsible for updating the sheet.

2. Production planning - [Minimum Audit Frequency = 2 X per Year] - ITP Sign Off = No

  • Current Date and Time.

  • Department Supervisor Name:

  • 2.1 Is there & who sets the Production Plan and maintains and monitors it?

  • 2.2 How does the Planner get CR's information & requirements for each product for that months casting production?

  • 2.3 Are there any regular production meetings to reviewing the performance of workshops to the plan and meeting notes issued?

  • 2.4 Who approves the plan for Production?

  • 2.5 Who gets a copy of the Plan?

  • 2.6 Are records maintained for all stages of the process for improvements?

  • 2.7 Is there a ITP and who issues this and ensures it is correct ?

3. Issue Tooling - [Minimum Audit Frequency = 2 X per Year] - ITP Sign Off = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 3.1 How is information transmitted to issue the correct pattern and core boxes to the Moulding Shop and who is responsible?

  • 3.2 Is there a current Production Plan in the area & how are the areas achievements reported?

  • 3.3 Are latest revision drawings available?

  • 3.4 Are the latest revision MDS available?

  • 3.5 What checks are carried out before release and is there a sign off?

  • 3.6 How is the pattern store informed if there is a modification required?

  • 3.7 How are Tooling / Methoding modifications & issues recorded?

4. Methods & Moulding - [Minimum Audit Frequency = 4 X per Year] - ITP Sign Off = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 4.1 Is there a current Production Plan in the area & how are the areas achievements reported?

  • 4.2 Are the cores manufactured the same time as the mould?

  • 4.3 How are the cores identified to the correct moulds?

  • 4.4 Is there a current mould method available in workshop?

  • 4.5 What checks are carried out before casting and is there a sign off?

  • 4.6 Material Checks & Calibration of equipment?

  • 4.7 How are the different heats identified?

5. Melting & Pouring - [Minimum Audit Frequency = 2 X per Year] - ITP Sign Off = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 5.1 Demonstrate how the material specification is achieved and how the steel sampling process in carried out?

  • 5.2 Can any evidence be shown of a completed melt & pour record sheet?

  • 5.3 Calibration of the Spectrometer. When was the last calibration and when is the next one due?

  • 5.4 Calibration of the Spectrometer. Have check samples been check before commencement of melting do they comply to the chemistry of the check sample?

  • 5.5 Is the steel refined in the AOD before being poured?

6. Chemistry - [Minimum Audit Frequency = 2 X per Year] - ITP Sign Off = Yes

  • Current Date and Time.

  • Department Supervisor Name:

  • 6.1 Can any evidence be shown of a completed Chemistry record sheet?

  • 6.2 How are non conforming Chemistries reported to YL technical supervisor?

  • 6.3 Who is responsible for the reporting of none complying test results to CR through a concession?

  • 6.4 What action is taken when a chemistry returns an aluminium level % > 0.030%? And who is notified?

7. Heat Treatment (Homogenise / Quench & Temper) - [Minimum Audit Frequency = 2 X per Year] - ITP Sign Off = 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?

  • 7.2 How is the product recognised to be ready for a specific heat treatment cycle?

  • 7.3 Is there a current MDS available?

  • 7.4 Is there a Photo or Drawing of a lip layout on the heat treatment tray and how it is welded to the tray and size of strong back material?

  • 7.5 Is each of the heat treatment cycles recorded on a chart and part & casting number recoded on it the heat treatment sheet for each load?

  • 7.6 Are test blocks and test bars placed on heat treatment tray and how are they recorded to be on the load?

  • 7.7 Is there any record sheet & photo for each Heat treatment load?

  • 7.8 Have stove to quench tank transfer times been recorded?

  • 7.9 Have recovery temperatures been recorded?

  • 7.10 When is the strong back material replaced?

  • 7.11 When are the oven calibrated & is there adequate thermocouples in oven?

  • 7.12 How is the Tempering temperature calculated?

8. NDT and Weld - [Minimum Audit Frequency = 2 X per Year] - ITP Sign Off = 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?

  • 8.2 Is there a current MDS available?

  • 8.3 Are the CR work instructions for U/T & MPI being used and followed for Lip castings?

  • 8.4 What CR specification is used to determine the acceptance criteria for the product & are operators qualified and records mainted?

  • 8.5 If a nonconforming indication is found by NDT on a casting what procedure is followed Pre Q&T & Post Q&T ?

  • 8.6 Are the MPI booths used and are the castings examined on the MPI stands?

  • 8.7 Which welders have been qualified to work on CR products and to what qualification and are there any records maintaned?

  • 8.8 Is the welding consumable being used compatible with CR weld procedures and are open packs kept in a maintained controlled oven (75-120°C) before use?

  • 8.9 If weld repairs are to be carried out are there any records to record casting temperatures during welding & are maps made to record location and size of all repairs?

  • 8.10 When is NDT performed after weld repair?

9. Met Release (Hardness & Mechanical) - [Minimum Audit Frequency = 4 X per Year] - ITP Sign Off = 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?

  • 9.2 Is there a current MDS available?

  • 9.3 How is it identified what test are carried out and from the CR Block & from the ASTM Test bar and the location where the samples are taken from?

  • 9.4 Where are the large test blocks stored after the test sections have been removed. Are they identified correctly?

  • 9.5 What CR specification is used to determine the acceptance criteria for the product?

  • 9.6 Who is responsible for reporting non complying test results from both the block and test bar?

  • 9.7 View previous non conforming test results and action taken?

  • 9.8 Calibration of all equipment up to date?

  • 9.9 Hardness Testing of all test bars is carried out using Brinell machine?

  • 9.10 Mechanical results ,hardness & test bar Chemical results are recorded? And are the witness by CR / TDES personnel?

  • 9.11 Mechanical results ,hardness & test bar Chemical testing is all carried out by qualified personnel. Are records maintained of all these personnel?

10. Fit & Gauge - [Minimum Audit Frequency = 4 X per Year] - ITP Sign Off = Yes

  • Select date

  • Department Supervisor Name:

  • 10.1 Who manages the gauges in the Store & are there records kept of calibration dates?

  • 10.2 Is there a current MDS available?

  • 10.3 Are the CR work instructions for Gauging being used and followed for each of the lip castings?

  • 10.4 Is there a final inspection carried out by the Foundry before CR\TDES do a release inspection?

  • 10.5 If a nonconforming fit is found by final or CR\TDES inspection in a gauged area what procedure is followed?

  • 10.6 Is the the installation of weldments carried out to CR's procedure ?

11. Dimensional Inspection - [Minimum Audit Frequency = 2 X per Year] - ITP Sign Off = Yes

  • Select date

  • Department Supervisor Name:

  • 11.1 Who is trained to measure HEX lips and are records kept ?

  • 11.2 What work instruction are you working to?

  • 11.3 Is the latest revision dimensional inspection drawing available and being used?

  • 11.4 When is a dimensional inspection carried out? Before homogenise? After homogenise? After quench?

  • 11.5 Is there a final inspection carried out by the Foundry before CR\TDES do a release inspection?

  • 11.6 If a nonconforming dimension is found after knock out, what action is taken?

  • 11.7 If a non complying dimension is found after quench, what action is taken?

  • 11.8 If a non complying dimension is found after homogenise, what action is taken?

12. Corrective Action Reports (CAR or NCR) & Concessions - [Minimum Audit Frequency = 2 X per Year] - ITP Sign Off = No

  • Select date

  • Department Supervisor Name:

  • 12.1 When is an internal CAR raised and who receives a copy?

  • 12.2 What time frame is allowed for the follow up and closure of a CAR/NCR?

  • 12.3 Who is authorised to close out a CAR/NCR and what actions need to be completed before a CAR/NCR can be closed out?

  • 12.4 What level of management is informed when a CAR/NCR is raised for non conforming customer product?

  • 12.5 When is a concession raised and who is informed of the concession?

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