General Manufacturing Welding Process Audit

Title Page

Document No.
Audit Title
Supplier Name
Supplier Contact
Supplier Contact Phone
Supplier Contact Email
Business
Conducted on
Prepared by (SQE)
Supplier Location
Personnel

DOCUMENTATION

1. Does the supplier have qualified Welding Procedure Specification(s)?
2. Does the Supplier know which customer process specifications are applicable to the work being completed?
3. Does the Supplier possess the current revision of the customers welding specification?
4. Does the supplier have a procedure that defines a welding control system?
5. Does the supplier possess the latest revision of the applicable codes governing WPS and Welder/Welding Operator qualification?
6. Does the Welder, Welding Operator or Tack Welder have access to the applicable approved WPS(s) for the job?
7. Are the WPS(s) in the native language of the Welder, Welding Operator or Tack Welder?
8. Can the Welder, Welding Operator or Tack Welder read and understand the content of the WPS(s)?
9. How does the Welder, Welding Operator or Tack Welder know that the WPS(s) they are using is/are the correct one(s) to be used for the specific job/assembly/part/joint?
10. For assemblies using 2 or more WPS(s) for different joints, is there documentation that clearly shows where each is to be used?
11. Are welding parameter settings available in the WPS (i.e. amps, volts, travel speed, etc.)?
12. Are the welding variable(s) displayed during welding or dialed in or programed for welding, within the approved parameter ranges listed in the WPS?
13. For mechanized or automatic welding, is the welding torch to part geometry set up to meet the WPS requirements?
14. Is the minimum preheat, minimum interpass and maximum interpass temperature measured and controlled?
15. How is the minimum preheat, minimum interpass and maximum interpass temperature measured and controlled?
16. Do travelers stay with the parts through out welding process?
17. Are cleaning procedures followed per the applicable specification and drawing requirements?
18. Are setup procedures followed per the applicable specifications and/or drawing requirements?
19. Does the Fitter, Welder and Inspector have access to approved work instructions ?
20. Is everyone working to the latest approved work instructions ?
21. Does the Welder, Welding Operator or Tack Welder inspect his work before releasing the part to the next operation?
22. If yes to above, do they follow a written procedure for inspection?
23. Is written Weld Acceptance Criteria available?
24. Is there documentation to support that the Welder, Welding Operator or Tack Welder is capable to do inspection?
25. Does a procedure for rework/repair welding exist?
26. Are appropriate weld measurement devices available to the Welder, Welding Operator or Tack Welder to determine if their weld(s) meet specified requirements?
27. Is rework welding done according to a WPS approved for rework/repair?
28. Are records of rework available?
29. If ISO certified or compliant, Does the Supplier know that welding is a special process to ISO 9000?
30. Does the Supplier track weld discontinuities by Process, Welder, Welding Operator or Tack Welder and Product?
31. Does the Supplier maintain a Continuous Improvement Plan to address the reduction of welding deviations?

EQUIPMENT-TOOL-INSTRUMENT-PROCESS

1. Are all fabrication fixture(s) properly identified and traceable to the parts they are intended for?
2. Is welding area clean and well organized?
3. Are there procedures and schedules in place for all welding equipment maintenance (Power Supplies, Wire Feeders, Positioners, etc.)?
4. Is the welding equipment on a regular maintenance and calibration schedule (yearly recommended).
5. Are records of required and performed maintenance and or calibration on file?
6. Do you have identifications of the calibration status present on each welding machine or device?
7. Are the weld machines well kept and maintained?
8. Are all welding parameter indicating devises or control displays traceable to a current calibration?
9. Are welding machines able to provide all the main process parameters?
10. Are all parameter indicators on the equipment functioning as intended.
11. Are standard welding work cable clamps used to complete the welding circuit? (not bare wire held against the part)
12. Are all welding circuit connections tight and periodically check for loosness to avoid overheated connections?
13. Is there applicable weld cleaning equipment in the welding area?
14. Do the weld preparations (both initial and back gouged preps) meet the customers drawing or specification requirements?
15. If the supplier fabricates Stainless Steel or Alloy or Non-Ferrous parts, are the materials and the tools used on them sufficiently segregated to prevent iron or copper cross contamination?
16. Where post weld heat treatment is required, does the Supplier have Post Weld Heat Treatment (PWHT) capability sufficient for the job?
17. Are all post weld heat treatment equipment temperature devises calibrated?
18. Where post weld heat treatment is required, does the supplier have a current furnace survey?
19. Is flat position (1G/F or 2F) welding use maximized?
20. If flat position (1G/F or 2F) welding is not exclusive, are the Welder, Welding Operator or Tack Welder(s) properly qualified for the applicable out of position welding (2G, 3, 4, 5 or 6 G/F)?
21. Are the welds inspected to the relevant customer requirements ?

MATERIALS

1. Are all welding filler materials properly labeled according to applicable specifications?
2. Do the filler materials meet the applicable customer requirements?
3. Is there a procedure in place to verify and review incoming welding and base material certifications before the material is released to production.
4. Are the covered electrodes stored in accordance with industry standards and specification requirements.
5. Is the temperature of each holding oven read and recorded at least once every day?
6. Are all other filler materials, including fluxes, stored such that they are protected from moisture contamination and uncontrolled temperature changes?
7. Are the weld filler materials and bare wire type electrodes stored in a manner to maintain their cleanliness, including spooled wire on welding stations in the production area?
8. For low hydrogen covered electrodes, are all open containers stored in a temperature controlled oven per code and manufactures requirements?
9. Are non-welding items stored in the covered electrode ovens (food, etc.)?
10. Does the supplier have a system/procedure to track the time that low hydrogen covered electrodes are checked out from the storage ovens or new containers?
11. Does this system/procedure adequately control how low hydrogen covered electrodes are rebaked or disposed of when the recommended out of oven times are exceeded?
12. Where required, do all filler materials, including fluxes, have available chemical and or property certification reports?
13. If recrushed or recycled flux(es) are being used, is this specifically approved by the customer in the welding documentation?
14. Is access to filler metal storage secured and controlled to prevent incorrect or uncontrolled filler material release?
15. Where compressed air is used to convey flux(es) or clean welding surfaces before welding, is it free of detrimental oil and moisture?
16. Does the applicable WPS gas type(s) conform with customer specification(s) and drawing requirements?
17. Were specified, do the applicable WPS gas type(s) conform to the customer purity requirements?
18. Is the gas flow rate checked?
19. For bulk feed gas systems, are all feed lines and equipment inspected for leaks at least once a year?
20. For all welding gases, are the lines, cylinders or tanks properly labeled as to the applicable gas content and or mixture?

OPERATORS

1. Does the Supplier possess WPQ records that show that the Welder, Welding Operator or Tack Welder using the (WPS) is qualified to use it per the applicable codes?
2. Does the supplier track and document Welder, Welding Operator or Tack Welder weld process performance continuity?
3. Are all Welders, Welding Operators or Tack Welders listed on a performance continuity tracking system, without gaps of more than 6 months?
4. Does each Welder, Welding Operator or Tack Welder have a stamp or identification number for traceability?
5. If welder stamps are not used, are records of Welder, Welding Operator or Tack Welder traceability produced and available?
6. Does the supplier have a process to track audit (sampling) NDT inspection that represents the applicable percentage of each welders work?
7. Does the supplier have an escalation process to increase inspection when defects are found during audit inspections?
8. Are Welding Supervisors former Welder/Welding Operators?l
9. If not, does the Welding Supervisor have any welding background training or experience?

SAFETY

1. Is use of proper PPE encouraged by the supplier (Safety Glasses, Helmets, Hard toe shoes, Filter mask, etc.)?
2. Does the supplier provide safety glasses, respirators and filter masks available for it's employees and visitors?
3. Is the shop clean?
4. Does the shop have adequate light intensity at the work surfaces to facilitate adequate welding workmanship?
5. Are walk ways, isles and corridors clear of obstructions?
6. Are the MSDS sheets for all chemicals in the welding area available for review?
7. Is there lifting and moving equipment available, if so is it clean and well maintained?
8. Do the lifting devices have serialized identification for inspection traceability and clearly stated load limits visible on them?
9. Are shop made or custom designed lifting devices made to specifications authorized by a certified Engineer?
10. Are all compressed gas cylinders secured to prevent falling during use and storage?
11. Are there sufficient welding flash screens around the welding area(s) to protect neighboring personnel from being exposed to arc flash hazards?
12. Are electrical disconnects for all welding equipment free from access restrictions?
13. Do all mechanized or automated welding systems have E-stop controls that are with in easy reach of the operator when they are in the typical operational position?
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