• Audit for - Medium / Large Sand Castings
    Continual Improvement
    Basic Supplier Audit Plan (Foundries)

    With the progression of Sand Castings in the manufacturing of Medium / Large 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.

1. Safety and Org Chart

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

  • 1.1. Do this site have an Emergency Response procedure or process? Who is responsible for this process?

  • 1.2. Explain the Emergency Response process for this site?

  • 1.3. Is there written procedures for Emergency Response?

  • 1.4. When last did this site test this Emergency Response Plan?

  • 1.5. Is the Safety Organization Chart up to date?

  • 1.6. How is emergency responsibilities communicated to personnel?

  • 1.7. Do you have a list of Emergency Personnel on the site?

  • 1.8. Is the Work Instruction clear (1 = No and Yes is 2)

  • Signature of person spoke too.

2. Process Flow

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

  • 2.1 Is the Process Flow applicable and up to date?

  • 2.2. Who is the Gatekeeper to keep this Process Flow up to date?

  • 2.2.1. Photo of Process Flow Gatekeeper.

  • 2.3. Is there anything that needs to be change on the Process Flow?

  • 2.4. Quality of Process Flow (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

3. Order, MDS & Drawing Control

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

  • 3.1. Who receives CR Purchase Orders from CR/TDES?

  • a. Name and Position is important.
    b. To explain and show the process in work environment.

  • 3.1.1. Photo of Purchase Order Receiver. (Name and Position)

  • 3.2. Are the PO's registered?

  • NO = EXPLANATION
    YES = NEED PROOF

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

  • NO = EXPLANATION
    YES = NEED PROOF
    Proof - Transmittal CR documents

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

  • How does the company report changes back to CR?

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

  • a. List of Receivers
    b. Document Control
    c. Proof is the Register

  • 3.6. Are records maintained relating to achieving deliveries on time?

  • NO = EXPLANATION
    YES = NEED PROOF
    Proof is the Register

  • 3.7. What method of reporting production updates is used for CR ?

  • a. Tracking sheet
    b. Who is responsible for updating the sheet.
    c. Proof of who receives and who sends.

  • 3.8. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

4. Production Planning

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • Name and Position

  • 4.1.1. Photo of Production Planner

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

  • a. What documents received (MDS?, Drawings? any other?)

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

  • NO = EXPLANATION
    YES = NEED PROOF
    Proof is the Meeting Minutes

  • 4.4. Who approves the plan for Production?

  • a. Name and Position
    b. Is there a formal procedure/instruction for this process?

  • 4.5. Who gets a copy of the Plan?

  • a. Name and Position.

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

  • a. Look and discuss color code. Red, Amber and Green.

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

  • a. This is only for Large Sand Castings.

  • 4.8. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

5. Issue Tooling

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • a. Name and Position.
    b. What tool is used to do this task?

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

  • NO = EXPLANATION
    YES = NEED PROOF
    Proof is the Production Plan

  • 5.3. Are latest revision drawings available?

  • a. How do you know that you have the latest drawing?
    b. Show proof of identifying latest revision.

  • 5.4. Are the latest revision MDS available?

  • a. This is for drawing confirmation only.

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

  • a. Proof of record sheet

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

  • a. Show process
    b. Job instruction Card

  • 5.7. How are Tooling / Methoding modifications & issues recorded?

  • a. Proof of record sheet

  • 5.8. Quality of Process Flow (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

6. Moulding

  • 6.8. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • NO = EXPLANATION
    YES = NEED PROOF
    Proof is the Production Plan and forward schedule

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

  • a. Show dates on production plan.
    b. 1 Day before, maximum 5 weeks prior to use.
    Recommended method is to put the date of core manufacturing date on core.

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

  • a. Part numbers as well as manufacturing date must be visible on part.
    b. Witness record sheet that goes to the pay master.

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

  • a. Production Plan.
    b. Methods Card easily available. (Visible and available to all operators).
    Ask an operator to show where the method cards is and how the system works.

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

  • a. Mould clean.
    b. Box clamped
    Proof is the Sign off sheet

  • 6.6 Material Checks & Calibration of equipment?

  • Proof of:
    a. Recording sheet
    b. Show the frequency of testing.
    Explain corrective action if out of spec.

  • 6.7 How are the different heats identified?

  • Look for method used:
    a. Sticker
    b. Hand writing
    Information to witness is:
    a. Date,
    b. Grade,
    c. Part number,
    d. Production Order Number

  • Signature of person spoke too.

7. Melting & Pouring

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • Show process and procedure

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

  • Proof is the record sheet

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

  • a. Evidence of last calibration
    Standard and daily check

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

  • Yes = Go ahead and pour.
    No = Show method of agjustment

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

  • Only applicable for Yinglui
    a. AOD is A - Argon, O - Oxygen and D - Degassing.
    For other foundries look at process of metal segregation.

  • 7.6. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

8. Chemistry

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • Proof is the Heat Sheet.
    a. First check is just before casting
    b. Final check is the results of the Test BAR
    c. How is the test BAR linked to the heat number and production plan?

  • 8.2 How are non conforming Chemistry reported to technical supervisor?

  • a. Who do you report too?
    b. Identification of problem and notification process.

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

  • Name of person that reports to CR.

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

  • a. Explain action process.
    b. Is this process in your instruction document?
    c. Who do you notify?

  • 8.5. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

9. Heat Treatment (Homogenize / Quench & Temper)

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • NO = EXPLANATION
    YES = NEED PROOF
    Proof is the Production Plan and forward schedule

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

  • 1. Proof of Heat treatment record sheet.
    2. Show segregation of different stages of Heat Treatment.
    Improvement: Is there Identification of color coding for different stages of the Heat Treatment Process?

  • 9.3 Is there a current MDS (Metallurgical Data Sheet) available?

  • 1. Show proof of MDS per product.
    2. Check revision.

  • 9.4 Is there a Photo or Drawing of product layout on the heat treatment tray and how it is stack / welded to the tray (Size of strong back material)?

  • 1. Proof of photos of stacking of product? (Different stacking method per product per foundry)
    2. Show method of stacking?

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

  • 1. Proof is the Heat treatment sheet relevant to MDS and date compared to production plan.
    2. Show Heat Treatment chart. (Proof) More hours is not a problem, less is.
    3 Stages of HT: (Must show proof of all).
    a. Homogenize
    b. Quenche
    c. Temper

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

  • 1. Photo of were test bars were loaded.
    2. Is this recorded on Heat Treatment Record?

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

  • 1. Not a requirement for GET but is for LIPS.

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

  • 1. Not a requirement for GET but is for LIPS.
    2. Do they know what the transfer time is?

  • 9.9 Have recovery temperatures been recorded?

  • 1. Proof is the recording on the Heat Treatment Sheet.
    2. Is the the infra red gun working correctly?

  • 9.10 When is the strong back material replaced?

  • 1. Not a requirement for GET but is for LIPS.

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

  • Proof is the calibration records of the Heat Treatment oven.

  • 9.12 How is the Tempering temperature calculated?

  • 1. Not a requirement for GET but is for LIPS.
    2. What is the spec on the MDS and can show how it works?

  • 9.13. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

10. NDT and Weld

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • NO = EXPLANATION
    YES = NEED PROOF
    Proof is the Production Plan and forward schedule

  • 10.2 Is there a current MDS available?

  • 1. Show proof of MDS per product.
    2. Check revision.

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

  • 1. Is the Work Instruction available at location?
    2. Are UT and MPI Operators trained? (Training Matrix)

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

  • 1. TS 082: Surface Finish Classification for CQMS Razer Sand Castings and TS 102: Ultrasonic Testing Requirements.
    2. Is the Work Instruction available at location?
    3. Are UT and MPI Operators trained? (Training Matrix)

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

  • 1. Proof of how NCR is recorded / reported.
    2. Proof of Welding Procedure Specification - Pre Q&T / Approved welders (Training Matrix).
    3. Do you do Post Q&T weld repairs? Show Welding Procedure Specification?

  • 10.6 Were is MPI performed?

  • 1. For dry powder and black ink - Typical for GET and small castings - Is lighting adequate (1000 Lux) idf not do they use a hand held light.
    2. When black light (Ultra Violet) is used, is this used in a dark room?

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

  • 1. Proof of Welding Procedure Specification - Approved welders (Training Matrix).
    2. Ask to see the welders and work area for CR Castings.

  • 10.8 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?

  • 1. Is the correct welding consumable used according to CR Welding Specification Procedure - Record the consumables and photo of weld procedure, if available.
    2. If stick welding is used, show area were consumables is kept (Should have oven set on 100 degrees C for storage of welding consumables).

  • 10.9 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?

  • 1. Not a requirement for GET but is for LIPS.
    2. Show evidence of previous LIP welding repair.
    3. Can you show me any LIPS being repair at the moment. (Need to see records of the process)

  • 10.10 When is NDT performed after weld repair?

  • 1. Record before or after Q&T.
    2. What is your acceptance range before Q&T of MPI / UT findings and what is the action?
    Rule of thumb is to repair all indications to the highest degree. before Q&T.

  • 10.11. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

11. Met Release (Hardness & Mechanical)

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • NO = EXPLANATION
    YES = NEED PROOF
    Proof is the Production Plan and forward schedule

  • 11.2 Is there a current MDS available?

  • 1. Show proof of MDS per product.
    2. Check revision.

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

  • 1. Are the test identified according to the most current MDS?
    2. Are they using CR Block and ASTM Test Bar and or other? See spec on MDS, Everything else is non-standard (other).
    3. Proof is photos of Bars being used.

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

  • Proof is the evidence were blocks and bars are stored.

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

  • 1. MDS

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

  • 1. Need to tell and show who the person is.
    2. The accountable person must show the process.

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

  • Visit NCR Register / Concession request

  • 11.8 Calibration of all equipment up to date?

  • Proof is the Calibration register and confirmation records.

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

  • 1. Who is responsible for this process?
    2. Is the machine calibrated?
    3. Do you use other machines to do hardness tests?

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

  • 1. Proof of records and inspection (Sign off and Photos)
    2. FC-012 Mechanical Testing, Inspection and Testing Procedure Form

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

  • Witness Training Matrix

  • 11.12. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

12. Fit & Gauge

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • 1. Need to see the person, witness calibration records on gauge and printout from CR for cross reference.
    2. Spot checks on gauges in store and in production.

  • 12.2 Is there a current MDS available?

  • 1. Show proof of MDS per product.
    2. Check revision.
    (If not , then it is OK)

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

  • Proof is the banners and work instructions.

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

  • 1. Witness records of release.
    2. FC-006 Adaptor Gauge & Fit Record Sheet

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

  • 1. Explain the process related to procedure.
    2. Who is responsible for this decision.

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

  • 1. This is for LIPS only.

  • 12.7. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

13. Dimensional Inspection (This is for LIPS only).

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • 1. This is for LIPS only.
    2. Meet the person.
    3. Training Matrix

  • 13.2 What work instruction are you working to?

  • Show document that you work according to.

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

  • 1. MDS
    2. Record the revision of drawing used during production.

  • 13.4 When is a dimensional inspection carried out?

  • 1. Before homogenise?
    2. After homogenise?
    3. After quench?
    4. All of the above.

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

  • Show record of signed release form.

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

  • 1, Who is responsible?
    2. Show evidence of previous ones.

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

  • 1. What action is taken?
    2. Is method of repair discussed and communicated to CR? Method of communication?

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

  • 1. What action is taken?
    2. Is method of repair discussed and communicated to CR? Method of communication?

  • 13.9. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

14. Corrective Action Reports

  • Current Date and Time.

  • Department Supervisor Name:

  • Photo of Department Supervisor

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

  • Show and interrogate NCR System.

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

  • Show and interrogate NCR System.

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

  • 1. Show and interrogate NCR System.
    2. Who is the person?

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

  • 1. Is this in your manual?

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

  • 1. Who notifies CR in what timeframe?

  • 14.6. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

15. Trial Process.

  • Current Date and Time.

  • 15.1 Who Looks after trials in the foundry?

  • To be introduced to person to gather the following information.

  • Department Supervisor Name:

  • Photo of Department Supervisor

  • 15.2 How do you know what is to be trialed?

  • 1. Information were the person gets the information relating to customer (CR) trials.
    2. Information on internal foundry trials to improve processes.

  • 15.3 Do you have a register/ log of all trials and the results?

  • Show evidence.

  • 15.4 What needs to be done for a trial and what needs to be recorded?

  • Where is the information found for you to determine what is required?

  • 15.5 Can you show me a trial card in use (If any and in the Workshop)?

  • Show evidence in workshop.

  • 15.6 Can you show a completed trial card from the register?

  • Show evidence.

  • 15.7 How are trial cards signed off.

  • Evidence of Customer trials And Foundry trials sign off.

  • 15.8. Quality of this process (Very Bad = 1, 2 = Bad, 3 = Adequate, 4 = Good, 5 = Very Good)

  • Signature of person spoke too.

OBSERVATIONS

  • What was seen, specific reverence to evidence.

RECOMMENDATIONS

  • Recommendations related to findings and according to specifications.

AREAS OF CONCERN AND PROPOSED CORRECTIVE ACTION

  • Describe actions that will be done to rectify non-conforming issues.

  • Has this action been added to the Non-Conforming Register to monitor progress and completion?

AUDIT SIGN OFF

  • Select date when all non-conformities will be complete.

  • Date of Audit completion.

  • Name of Accountable Person for Non-Conforming Issues.

  • Signature of of Accountable Person for Non-Conforming Issues.

  • Name of Auditor.

  • Signature of Auditor.

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