Shop Process Audit

• Conducted on

  Date

• Prepared by

• Location
  Address

Safety – Observe all operators are working safely

• Name Audited

• 1. Employees’ using correct PPE, as appropriate to their work station

  Yes

  No

  N/A

• 2. Workers in the area understand the 6S principles

  Yes

  No

  N/A

Receiving Observe parts being received

• Name Audited

• 1. Parts compared to purchase orders

  Yes

  No

  N/A

• 2. Wrong/Damaged parts quarantined and reported to team leader

  Yes

  No

  N/A

• 3. Evidence of SIR being performed

  Yes

  No

  N/A

• 4. Check SOP revision level to what is posted on SharePoint

  Yes

  No

  N/A

• 5. Workers in the area understand the 6S principles

  Yes

  No

  N/A

Storeroom Observe parts being put away

• Name Audited

• 1. Parts compared to AX location and put away in proper location

  Yes

  No

  N/A

• 2. Damaged parts quarantined and reported to team leader

  Yes

  No

  N/A

• 3. Cycle counting evidence

  Yes

  No

  N/A

• 4. Workers in the area understand the 6S principles

  Yes

  No

  N/A

Kitting Observe parts kit being assembled

• Name Audited

• 1. Parts compared to AX pick list and drawing BOM

  Yes

  No

  N/A

• 2. Damaged parts quarantined and reported to team leader

  Yes

  No

  N/A

• 3. Care taken to avoid damaging parts

  Yes

  No

  N/A

• 4. Workers in the area understand the 6S principles

  Yes

  No

  N/A

Wire Prep (Cut, Label, Strip, Terminate) Observe wire being prepared

• Name Audited

• 1. Traveler (list of process steps requiring quality signoffs) in use

  Yes

  No

  N/A

• 2. Operator trained on Komax Kappa and Mechtrix

  Yes

  No

  N/A

• 3. Operator checking document revision levels (SOP's, WI's, PM's, Visual Aids, etc.) to what is posted on SharePoint

  Yes

  No

  N/A

• 4. Wire checked for damage as fed to KOMAX

  Yes

  No

  N/A

• 5. KOMAX cutting blade free of nicks

  Yes

  No

  N/A

• 6. Wire checked for correct length

  Yes

  No

  N/A

• 7. Wire checked for legibility of print and correct ”TOFROM” label

  Yes

  No

  N/A

• 8. Wire checked for absence of nicks

  Yes

  No

  N/A

• 9. Daily Crimp verification being performed and conformance verified

  Yes

  No

  N/A

• 10. Crimp Press operated at standard settings for applicator/terminal/wire combination

  Yes

  No

  N/A

• 11. Evidence that Weekly PMs are being performed

  Yes

  No

  N/A

• 12. Pull Tester checked for calibration

  Yes

  No

  N/A

• 13. Crimp Height Micrometer checked for calibration

  Yes

  No

  N/A

• 14. Operator checking crimps under magnification for visual conformance

  Yes

  No

  N/A

• 15. Workers in the area understand the 6S principles

  Yes

  No

  N/A

Wire Prep (Cut, Label, Strip, Terminate) Observe wire being prepared

• Name Audited

• 1. Cable checked for correct length

  Yes

  No

  N/A

• 2. Cable checked for correct label

  Yes

  No

  N/A

• 3. Operator checking document revision levels (SOP's, WI's, PM's, Visual Aids, etc.) to what is posted on SharePoint

  Yes

  No

  N/A

• 4. Cable checked for under magnification for absence of nicks

  Yes

  No

  N/A

Sub Assembly Build

• Name Audited

• 1. Traveler (list of process steps requiring quality signoffs) in use

  Yes

  No

  N/A

• 2. Operator checking document revision levels (SOP's, WI's, PM's, Visual Aids, etc.) to what is posted on SharePoint

  Yes

  No

  N/A

• 3. Wire twisted to CES 18227 standards (twist length tolerance level, +/ 2 mm)

  Yes

  No

  N/A

• 4. Build sequence followed as listed on work instruction and build board

  Yes

  No

  N/A

• 5. Proper terminal insertion techniques used

  Yes

  No

  N/A

• 6. Subassembly braid conforming (no visible wires)

  Yes

  No

  N/A

• 7. Workers in the area understand the 6S principles

  Yes

  No

  N/A

Splice (Ultrasonic Welding)

• Name Audited

• 1. Machine startup checks completed (no air leaks, air blowdown, daily cleaning)

  Yes

  No

  N/A

• 2. Operator trained on Ultrasonic Welder

  Yes

  No

  N/A

• 3. Operator checking document revision levels (SOP's, WI's, PM's, Visual Aids, etc.) to what is posted on SharePoint

  Yes

  No

  N/A

• 4. Evidence that Weekly PMs are being performed

  Yes

  No

  N/A

• 5. Wire checked for absence of nicks

  Yes

  No

  N/A

• 6. Daily Weld verification being performed and conformance verified

  Yes

  No

  N/A

• 7. Machine operated at standard setting for each splice

  Yes

  No

  N/A

• 8. Operator checking welds under magnification for visual conformance

  Yes

  No

  N/A

• 9. Heat shrink only (no tape under shrink)

  Yes

  No

  N/A

• 10. Workers in the area understand the 6S principles

  Yes

  No

  N/A

Final Assembly Build

• Name Audited

• 1. Proper terminal insertion techniques used (pushclickpull)

  Yes

  No

  N/A

• 2. Spiral wrap in conformance with CES18227 standard

  Yes

  No

  N/A

• 3. Operator checking document revision levels (SOP's, WI's, PM's, Visual Aids, etc.) to what is posted on SharePoint

  Yes

  No

  N/A

• 4. Harness label applied in conformance with CES18227 standard

  Yes

  No

  N/A

Pre Braid Test

• Name Audited

• 1. Test board / spider checked for damage

  Yes

  No

  N/A

• 2. Device under test checked for damage before connecting

  Yes

  No

  N/A

• 3. Operator checking document revision levels (SOP's, WI's, PM's, Visual Aids, etc.) to what is posted on SharePoint

  Yes

  No

  N/A

• 4. Cirris Easy Wire/ Easy Touch operated at standard setting

  Yes

  No

  N/A

• 5. Device under test checked for damage after connecting

  Yes

  No

  N/A

Harness Braid

• Name Audited

• 1. Main section braid conforming (no visible wires)

  Yes

  No

  N/A

• 2. Braiding applied over roundit

  Yes

  No

  N/A

• 3. Operator checking document revision levels (SOP's, WI's, PM's, Visual Aids, etc.) to what is posted on SharePoint

  Yes

  No

  N/A

• 4. Dimensions of breakouts conforming

  Yes

  No

  N/A

• 5. Evidence that Daily (8 hr) and Weekly (40 hr) PMs are being performed

  Yes

  No

  N/A

Post Braid Test

• Name Audited

• 1. Test board / spider checked for damage

  Yes

  No

  N/A

• 2. Device under test checked for damage before connecting

  Yes

  No

  N/A

• 3. Operator checking document revision levels (SOP's, WI's, PM's, Visual Aids, etc.) to what is posted on SharePoint

  Yes

  No

  N/A

• 4. Cirris Easy Wire/ Easy Touch operated at standard setting

  Yes

  No

  N/A

• 5. Device under test checked for damage after connecting

  Yes

  No

  N/A

Final Accessories

• Name Audited

• 1. All brackets installed

  Yes

  No

  N/A

• 2. All fuses and sensors installed

  Yes

  No

  N/A

• 3. Pclips installed at correct location and orientation

  Yes

  No

  N/A

• 4. Cable ties tightened at correct tension

  Yes

  No

  N/A

• 5. Torque wrench used at correct torque value

  Yes

  No

  N/A

• 6. Torque value recorded on traveler

  Yes

  No

  N/A

PreShipment Verification (CMRUS 100% Inspection)

• Name Audited

• 1. Traveler completed

  Yes

  No

  N/A

• 2. Label conforms to drawing

  Yes

  No

  N/A

• 3. All components present

  Yes

  No

  N/A

• 4. All locks engaged and in proper position

  Yes

  No

  N/A

• 5. Witness marks applied

  Yes

  No

  N/A

• 6. PPA conforms to all notes and details

  Yes

  No

  N/A

• 7. Source Release Documentation collected and sent to Cummins

  Yes

  No

  N/A

Packaging

• Name Audited

• 1. Packaging Standard in Use

  Yes

  No

  N/A

• 2. New packaging (no reused packaging)

  Yes

  No

  N/A

• 3. All connectors protected with bubble wrap

  Yes

  No

  N/A

• 4. Check SOP revision level to what is posted on SharePoint

  Yes

  No

  N/A

• 5. Harness sealed in polyethylene sleeve (corrosion protection)

  Yes

  No

  N/A

• Comments:

• Actions: