QMS Internal Audit

• Site conducted

  Select

• Patterns

• Foundry - DC1

• Foundry - DC2

• Foundry - DC3

• Fettling

• Conducted on

  Date

• Prepared by

• Date

  Date

• Auditee names

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Are all patterns and coreboxes suitably identified ?

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is storage location recorded ?

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How are incoming patterns handled ?

• How are any pattern work requirements documented

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate that the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Date

  Date

• Auditee names

• Is the mixer area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Is the laboratory area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• What raw materials are used

• What raw material certification is provided by suppliers ?

• What sand tests are carried out

• How often are the sand tests done

• Are actions taken if results are outside defined limits ?

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are actions documented ?

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Do the results indicate the process is in control ?

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• When was the mixer last calibrated ?

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Date

  Date

• Auditee names

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Is a route card available ?

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the corebox checked before use

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How does the operator know how the core needs to be made ? (irons, chills etc)

• How does the operator know when to strip the core ?

• Does the core get inspected after stripping and what is the operator looking for ?

• How is the core identified ?

• How is the core coated ?

• Are baume coating checks carried out the coating ?

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are the baume checks within limits ?

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How does the operator determine that the core is coated and acceptable for use ?

• Is the route card signed off and by who ?

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate that the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Date

  Date

• Auditee Names

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Is the route card available

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Check the coating type in use

• How many coats are applied

• What is the drying time between coats

• What checks are made after each coat

• Is route card signed off once coating is complete and poly released for production

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Document Control

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• Does the evidence indicate that the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Date

  Date

• Auditee Names

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Is route card available

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is daily plan available

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How is the method instruction communicated

• Is the prescribed method for the parts being rammed being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How is the strip time determined ?

• Is pattern release being used ?

• How is the moulding box size determined ?

• How long is each mould allowed to cure ?

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate that the process map is being followed

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• Date

  Date

• Auditees

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Are route cards available

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How are the moulds coated

• Are baume checks carried out on the coating

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• Are baume checks within limits

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• What is the mould checked for to determine if its acceptable

• How does the moulder know if cores are required and which cores are for which mould

• Are cores available and acceptable

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How are cores assembled into the mould

• How does the moulder know if there are any special requirements (eg. ingates, filters, inoculant etc)

• Are 2 people are involved in closing the mould to ensure correct positioning of cope on drag (observe)

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the mould closed and then opened to check for crush, sand etc (observe)

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• What determines whether are fixed (C-clamp) or adjustable (carver clamp) are used

• What determines if mould weights are used and how is this communicated to the moulder

• Is the route card signed off and by who ?

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate that the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

Melt Planning

• Date

  Date

• Auditee(s)

• Are route cards available

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the melt plan match the route cards

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the melt plan contain the required information for furnace charges

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are the requirements for testing defined (test bars etc)

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the pouring temperature defined for each pour

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

Charging, Melting & Pouring

• Date

  Date

• Auditees

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Are charge weights recorded and correct to melt plan

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• What determines if Redux needs to be added and to what frequency is it added

• Are the furnace loadcells in calibration

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Last loadcell calibration dates

• DC2/3 only - is 0.1% pre-seed added to SG iron charges

• Is tapping temperature recorded and in line with melt plan requirements

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is thermal analysis sample taken and recorded (total carbon & silicon content) and in line with melt plan requirements

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How do the melt team know the ladle treatment requirements for the melt (MgFeSi, inoculant etc)

• Is the iron temperature checked before pouring and correct to melt plan

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are the pyrometers and QuikLab in calibration

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Last pyrometer / QuikLab calibration dtaes

• Is a test bar poured at the end of pouring when required

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How is the test bar/keel block identified

• Is a nodularity test sample poured at the end of pouring when required for SG iron

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Check the nodularity test records in the lab - are they recorded against melt code and 85% min nodularity

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• If any nodularity results are <85% what actions have been taken

• Is a spectrometer sample cast and identified against melt code

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the chemistry checked using the spectrometer

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the spectrometer calibration checked using standard samples

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• List spectrometer standard samples in use and drift check dates for last 5 min checks

• Are the chemistry results in line with metallurgist requirements

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the melt record completed and signed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the route card completed and signed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is there any evidence that corrective actions have been required and taken as prescribed (HT, concess, scrap etc)

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• List some examples if applicable

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate that the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Date

  Date

• Auditees

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Is the time from pouring to KO defined on the route card

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is this time being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Record examples

• Is the casting visually checked at KO

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are visually defective castings identified and segregated

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are different material types segregated at KO (runners, feeders etc)

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• Which types of material

• If specified on the route card, how is the temperature of the casting checked before KO

• Is the sand recycled

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• DC1/DC3 only - is the moulding box checked for damage after KO and sent for repair if required

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the route card completed and signed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate that the process map is being followed

  Select Yes No N/A

  • Yes
  • No
  • N/A

• Date

  Date

• Auditees

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• How is the casting temperature deemed to be low enough for shotblasting

• What determines which shotblast unit (or sub-con) will be used

• Is the shotblast quality acceptable (typically Sa 2 1/2)

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are visually defective castings identified and segregated at shotblasting

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are castings shotblasted after fettling

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• How is this decided

• Is the route card completed and signed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate that the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Date

  Date

• Auditees

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Is the route card available

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the casting visually inspected during fettling

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are written instructions / visual aids / gauges / used for fettling

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Examples

• Are defective castings segregated

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• Is HAV's monitoring of each fettling step utilising a powered tool carried out

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the route card completed and signed

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• Document Control

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• Does the evidence indicate that the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Date

  Date

• Auditees

• Is the area tidy, clean and organised

  Good

  Fair

  Poor

  N/A

• Is the route card available

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are any other documents required (standards, specifications, drawings etc) and available

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are part/customer specific inspection/test requirements communicated via the route card

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are all required inspections completed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Are non conforming parts place in quarantine

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the route card completed and signed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate that the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Date

  Date

• Auditees

• Is the route card available

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the route card indicate the painting requirement

  Yes / OK

  No / Not OK

  Opportunity for Improvement

  NC Raised

  N/A

• Check the paint and application are as required (observe)

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Is the route card completed and signed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Document Control

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A

• Does the evidence indicate that the process map is being followed

  Select Yes / OK No / Not OK Opportunity for Improvement NC Raised N/A

  • Yes / OK
  • No / Not OK
  • Opportunity for Improvement
  • NC Raised
  • N/A