LSW - PROTOTYPE - DO NOT USE

• Site conducted

  Select

• Conducted on

  Date

• Prepared by

• Validate & Communicate Clear to Build

  Compliant

  Non-Compliant

  N/A

• Set daily schedule

  Compliant

  Non-Compliant

  N/A

• Update Tier board metrics

  Compliant

  Non-Compliant

  N/A

Daily HUDDLE

• PPE

  Compliant

  Non-Compliant

  N/A

• Headcount

  Compliant

  Non-Compliant

  N/A

• SQDIP Boards meeting

  Compliant

  Non-Compliant

  N/A

• Review Corrective Action Projects (C/Ms list, FAST...)

  Compliant

  Non-Compliant

  N/A

• Validate attendance list

  Compliant

  Non-Compliant

  N/A

• 5S +Safety Walk

  Compliant

  Non-Compliant

  N/A

• What area are you going to be auditing?

  Select Tank and Canopy Fabrication Coil Dept Final Assembly Spot Welding Welding Paint Ends

  • Tank and Canopy
  • Fabrication
  • Coil Dept
  • Final Assembly
  • Spot Welding
  • Welding
  • Paint
  • Ends

• What station will you be auditing today?

  Select Cell 1 Tank Fixture Cell 1 Baseframe Cell 1 Marriage Cell 1 Canopy Fixture Cell 2 Tank Fixture Cell 2 Baseframe Cell 2 Marriage Cell 2 Canopy Fixture Cell 3 Tank Fixture Cell 3 Baseframe Cell 3 Marriage Cell 3 Canopy Fixture Cell 1.5 Tank Fixture Cell 4 Tank Fixture Cell 4 Baseframe Cell 4 Marriage K&L Sub-Assembly

  • Cell 1 Tank Fixture
  • Cell 1 Baseframe
  • Cell 1 Marriage
  • Cell 1 Canopy Fixture
  • Cell 2 Tank Fixture
  • Cell 2 Baseframe
  • Cell 2 Marriage
  • Cell 2 Canopy Fixture
  • Cell 3 Tank Fixture
  • Cell 3 Baseframe
  • Cell 3 Marriage
  • Cell 3 Canopy Fixture
  • Cell 1.5 Tank Fixture
  • Cell 4 Tank Fixture
  • Cell 4 Baseframe
  • Cell 4 Marriage
  • K&L Sub-Assembly

• Last foam shot on ratio monitor within specifications (87% - 97%)?

  Compliant

  Non-Compliant

  N/A

• Foam gun head clean and free of dried foam?

  Compliant

  Non-Compliant

  N/A

• Does work station have standard work posted?

  Yes

  No

  N/A

• Does the associate(s) know where the standard work is located?

  Yes

  No

  N/A

• Does the standard work include Critical to Quality (CTQ) identifiers?

  Yes

  No

  N/A

• Can the associate describe why CTQ items are important or what the significance is?

  Yes

  No

  N/A

• Explain CTQ for station to associate - why is item critical to quality, what actions should the associate take if non-compliant?

• Does the associate have the required tools/fixtures to perform the required task(s)?

  Yes

  No

  N/A

• What tool(s) are missing?

• Are fixtures/tools in good working condition to perform required task(s)?

  Yes

  No

  N/A

• Is the associate using the tools/fixtures according to standard work?

  Yes

  No

  N/A

• Are all required parts available within the work station?

  Yes

  No

  N/A

• Is the associate following the standard work procedure?

  Yes

  No

  N/A

• Is the work station kept in an organized and clean manner?

  Yes

  No

  N/A

• Are there any safety hazards present in the work station?

  Safe

  At Risk

  N/A

• Does the final product meet Quality standards?

  Yes

  No

  N/A

• Does work station have standard work posted?

  Yes

  No

  N/A

• Does the associate know where the standard work is located?

  Yes

  No

  N/A

• Does the associate have the required tools/fixtures to perform the required task(s)

  Yes

  No

  N/A

• What is missing?

• Material type of parts matches what is required on travel document

  Compliant

  Non-Compliant

  N/A

• Amada brake press die holders in sequential order on press

  Compliant

  Non-Compliant

  N/A

• Punch tooling shimmed to correct height?

  Yes

  No

  N/A

• Part quantity on travel document matches quantity produced

  Compliant

  Non-Compliant

  N/A

• Brake top and bottom dies tight together and undamaged

  Compliant

  Non-Compliant

  N/A

• Parts free of burrs across edges of parts

  Compliant

  Non-Compliant

  N/A

• Can associate correctly demonstrate measuring with a universal protractor to the nearest 5 minutes of a degree?

  Yes

  No

  N/A

• Demonstrate how to use protractor correctly - Why is it important to target center of specification limits?

• Can associate correctly demonstrate measuring with a dial or digital caliper to the nearest 0.001"

  Yes

  No

  N/A

• Demonstrate how to use caliper correctly - Have associate explain what 0.001" is. Why is it important to target center of specification limits?

• Is the work station kept in an organized and clean manner?

  Yes

  No

  N/A

• Are there any safety hazards present in the station?

  Safe

  At Risk

  N/A

• Does the final product meet Quality and blueprint standards?

  Yes

  No

  N/A

• Comments

• What work station is being audited today?

• Does the work station have standard work posted?

  Yes

  No

  N/A

• Does the associate know where the standard work is located?

  Yes

  No

  N/A

• Does standard work include Critical to Quality (CTQ) identifiers?

  Yes

  No

  N/A

• Can the associate describe why CTQ items are important or what the significance is?

  Yes

  No

  N/A

• Explain CTQ for station to associate - why is item critical to quality, what actions should the associate take if non-compliant?

• Does the associate have the required tools/fixtures to perform the required tasks?

  Yes

  No

  N/A

• Are fixtures/tools in good working condition to perform required tasks?

  Yes

  No

  N/A

• Is the associate(s) following standard work procedure?

  Yes

  No

  N/A

• Is the station kept in an organized and clean manner?

  Yes

  No

  N/A

• Are there any safety hazards present in the station?

  Safe

  At Risk

  N/A

• Does final product meet Quality Standards?

  Yes

  No

  N/A

• Brazers are using Nitrogen purge when brazing

  Compliant

  Non-Compliant

  N/A

• What flow rate is Nitrogen purge set at?

• Valves are wrapped in wet cloth during brazing process

  Compliant

  Non-Compliant

  N/A

• Check valve orientation (direction of flow) correct

  Compliant

  Non-Compliant

  N/A

• Solenoid valve orientation (direction of flow) correct

  Compliant

  Non-Compliant

  N/A

• Solenoid coil voltage matches order requirement

  Compliant

  Non-Compliant

  N/A

• Probes secured tightly suction line (if applicable) with 3 tie straps

  Compliant

  Non-Compliant

  N/A

• Probes located in the correct position

  Compliant

  Non-Compliant

  N/A

• Leak testers checking each braze joint with sniffer

  Compliant

  Non-Compliant

  N/A

• Final pressure documented on coil pressure tag

  Compliant

  Non-Compliant

  N/A

• Defrost heaters are secured on heater brackets. All tabs are bent back to prevent heaters from falling off of the brackets.

  Compliant

  Non-Compliant

  N/A

• Comments

• Which work station are you auditing today?

• Does work station have standard work posted?

  Yes

  No

  N/A

• Does the associate know where the standard work is located?

  Yes

  No

  N/A

• Does standard work include Critical to Quality (CTQ) identifiers?

  Yes

  No

  N/A

• Can the associate describe why CTQ items are important or what the significance is?

  Yes

  No

  N/A

• Explain CTQ for station to associate - why is item critical to quality, what actions should the associate take if non-compliant?

• Does the associate have the required tools/fixtures to perform the required tasks?

  Yes

  No

  N/A

• Are fixtures/tools in good working condition to perform required tasks?

  Yes

  No

  N/A

• Is the associate using the tools/fixtures according to standard work?

  Yes

  No

  N/A

• Are all required parts available within the station?

  Yes

  No

  N/A

• Is the associate(s) following standard work procedure?

  Yes

  No

  N/A

• Is the station kept in an organized and clean manner?

  Yes

  No

  N/A

• Are there any safety hazards present in the station?

  Safe

  At Risk

  N/A

• Does final product meet Quality Standards?

  Yes

  No

  N/A

• Comments

• Does work station have standard work posted?

  Yes

  No

  N/A

• Does the associate know where the standard work is located?

  Yes

  No

  N/A

• Does standard work include Critical to Quality (CTQ) identifiers?

  Yes

  No

  N/A

• Can the associate describe why CTQ items are important or what the significance is?

  Yes

  No

  N/A

• Explain CTQ for station to associate - why is item critical to quality, what actions should the associate take if non-compliant?

• Does the associate have the required tools/fixtures to perform the required tasks?

  Yes

  No

  N/A

• Are fixtures/tools in good working condition to perform required tasks?

  Yes

  No

  N/A

• Is the associate using the tools/fixtures according to standard work?

  Yes

  No

  N/A

• Is the associate(s) following standard work procedure?

  Yes

  No

  N/A

• Is the station kept in an organized and clean manner?

  Yes

  No

  N/A

• Are there any safety hazards present in the station?

  Safe

  At Risk

  N/A

• Does final product meet Quality Standards?

  Yes

  No

  N/A

• Shelf tops free of dents cuased by welder electrodes

  Yes

  No

  N/A

• Welded shelves fit fixture cart withtout forcing

  Yes

  No

  N/A

• Shelf twist testing does not break spot welds

  Yes

  No

  N/A

• Shelf size matches case order

  Yes

  No

  N/A

• Associates are performing weld nugget verification test periodically?

  Yes

  No

  N/A

• Does work station have standard work posted?

  Yes

  No

  N/A

• Does the associate know where the standard work is located?

  Yes

  No

  N/A

• Does standard work include Critical to Quality (CTQ) identifiers?

  Yes

  No

  N/A

• Can the associate describe why CTQ items are important or what the significance is?

  Yes

  No

  N/A

• Explain CTQ for station to associate - why is item critical to quality, what actions should the associate take if non-compliant?

• Does the associate have the required tools/fixtures to perform the required tasks?

  Yes

  No

  N/A

• Are fixtures/tools in good working condition to perform required tasks?

  Yes

  No

  N/A

• Is the associate using the tools/fixtures according to standard work?

  Yes

  No

  N/A

• Is the associate(s) following standard work procedure?

  Yes

  No

  N/A

• Components sit in welding fixtures securely and flush to adjacent parts (where applicable)

  Yes

  No

  N/A

• Robotic welds complete and without voids (on case frames)

  Yes

  No

  N/A

• Is the station kept in an organized and clean manner?

  Yes

  No

  N/A

• Are there any safety hazards present in the station?

  Safe

  At Risk

  N/A

• Does final product meet Quality Standards?

  Yes

  No

  N/A

• Does work station have standard work posted?

  Yes

  No

  N/A

• Does the associate know where the standard work is located?

  Yes

  No

  N/A

• Does standard work include Critical to Quality (CTQ) identifiers?

  Yes

  No

  N/A

• Can the associate describe why CTQ items are important or what the significance is?

  Yes

  No

  N/A

• Explain CTQ for station to associate - why is item critical to quality, what actions should the associate take if non-compliant?

• Does the associate have the required tools/fixtures to perform the required tasks?

  Yes

  No

  N/A

• Are fixtures/tools in good working condition to perform required tasks?

  Yes

  No

  N/A

• Is the associate(s) following standard work procedure?

  Yes

  No

  N/A

• Is the work station kept in an organized and clean manner?

  Yes

  No

  N/A

• Is paint coverage within specifications (smooth 1.8 -3.0 mils) .. (river texture avg 2.5 -4.0 mils)

  Compliant

  Non-Compliant

  N/A

• Are there any paint surface flaws … visual … check for contamination, powder surge, tape residue, scratches, dents, faraday areas properly covered

  Compliant

  Non-Compliant

  N/A

• Hook condition … are hooks clean, free from excessive paint build up

  Compliant

  Non-Compliant

  N/A

• A-racks and carts … are parts safely secured in correct A-Rack, basket or cart and tagged to go to the correct assembly line

  Compliant

  Non-Compliant

  N/A

• Paint line Baths systems running smooth, spraying and up to temperature

  Compliant

  Non-Compliant

  N/A

• Dry Off Ovens clear of debris and up to temperature.

  Compliant

  Non-Compliant

  N/A

• Are there any safety hazards present in the station?

  Safe

  At Risk

  N/A

• Does final product meet Quality Standards?

  Yes

  No

  N/A

• Comment

• Does work station have standard work posted?

  Yes

  No

  N/A

• Does the associate know where the standard work is located?

  Yes

  No

  N/A

• Does standard work include Critical to Quality (CTQ) identifiers?

  Yes

  No

  N/A

• Can the associate describe why CTQ items are important or what the significance is?

  Yes

  No

  N/A

• Explain CTQ for station to associate - why is item critical to quality, what actions should the associate take if non-compliant?

• Does the associate have the required tools/fixtures to perform the required tasks?

  Yes

  No

  N/A

• Are fixtures/tools in good working condition to perform required tasks?

  Yes

  No

  N/A

• Is the associate using the tools/fixtures according to standard work?

  Yes

  No

  N/A

• Is the associate(s) following standard work procedure?

  Yes

  No

  N/A

• Is the station kept in an organized and clean manner?

  Yes

  No

  N/A

• Foam ratio on monitor was verified with bag shot at start of shift

  Compliant

  Non-Compliant

  N/A

• Head of foam gun is clean and free of foam (cleaned after each group of shots)

  Compliant

  Non-Compliant

  N/A

• No foam voids in end panels (check corners)

  Compliant

  Non-Compliant

  N/A

• End skins free from paint defects (light paint, heavy paint, spots)

  Compliant

  Non-Compliant

  N/A

• Work order is attached to the end and the number is visible on the front of the end

  Compliant

  Non-Compliant

  N/A

• End skin paint color matches work order

  Compliant

  Non-Compliant

  N/A

• Ends are free of damage

  Compliant

  Non-Compliant

  N/A

• End skins are free of excess swiggle and tape

  Compliant

  Non-Compliant

  N/A

• End skins are aligned

  Compliant

  Non-Compliant

  N/A

• End trim covers edges of both skins

  Compliant

  Non-Compliant

  N/A

• End trim is secured tightly in the inside radius features

  Compliant

  Non-Compliant

  N/A

• There is no gap in the end trim joint (at bottom of end)

  Compliant

  Non-Compliant

  N/A

• PVC end trim is smooth on all corners

  Compliant

  Non-Compliant

  N/A

• Are there any safety hazards present in the station?

  Safe

  At Risk

  N/A

• Does final product meet Quality Standards?

  Safe

  At Risk

  N/A

• Validate plan execution (Shipment)

  Compliant

  Non-Compliant

  N/A

• Time keeping/ Absenteeism Reporting/ PPOD Sheet/ Integrity Counts

  Compliant

  Non-Compliant

  N/A