Safety – Observe all operators are working safely

  • Name Audited

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

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

Receiving Observe parts being received

  • Name Audited

  • 1. Parts compared to purchase orders

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

  • 3. Evidence of SIR being performed

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

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

Storeroom Observe parts being put away

  • Name Audited

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

  • 2. Damaged parts quarantined and reported to team leader

  • 3. Cycle counting evidence

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

Kitting Observe parts kit being assembled

  • Name Audited

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

  • 2. Damaged parts quarantined and reported to team leader

  • 3. Care taken to avoid damaging parts

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

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

  • Name Audited

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

  • 2. Operator trained on Komax Kappa and Mechtrix

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

  • 4. Wire checked for damage as fed to KOMAX

  • 5. KOMAX cutting blade free of nicks

  • 6. Wire checked for correct length

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

  • 8. Wire checked for absence of nicks

  • 9. Daily Crimp verification being performed and conformance verified

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

  • 11. Evidence that Weekly PMs are being performed

  • 12. Pull Tester checked for calibration

  • 13. Crimp Height Micrometer checked for calibration

  • 14. Operator checking crimps under magnification for visual conformance

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

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

  • Name Audited

  • 1. Cable checked for correct length

  • 2. Cable checked for correct label

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

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

Sub Assembly Build

  • Name Audited

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

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

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

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

  • 5. Proper terminal insertion techniques used

  • 6. Subassembly braid conforming (no visible wires)

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

Splice (Ultrasonic Welding)

  • Name Audited

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

  • 2. Operator trained on Ultrasonic Welder

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

  • 4. Evidence that Weekly PMs are being performed

  • 5. Wire checked for absence of nicks

  • 6. Daily Weld verification being performed and conformance verified

  • 7. Machine operated at standard setting for each splice

  • 8. Operator checking welds under magnification for visual conformance

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

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

Final Assembly Build

  • Name Audited

  • 1. Proper terminal insertion techniques used (pushclickpull)

  • 2. Spiral wrap in conformance with CES18227 standard

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

  • 4. Harness label applied in conformance with CES18227 standard

Pre Braid Test

  • Name Audited

  • 1. Test board / spider checked for damage

  • 2. Device under test checked for damage before connecting

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

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

  • 5. Device under test checked for damage after connecting

Harness Braid

  • Name Audited

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

  • 2. Braiding applied over roundit

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

  • 4. Dimensions of breakouts conforming

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

Post Braid Test

  • Name Audited

  • 1. Test board / spider checked for damage

  • 2. Device under test checked for damage before connecting

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

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

  • 5. Device under test checked for damage after connecting

Final Accessories

  • Name Audited

  • 1. All brackets installed

  • 2. All fuses and sensors installed

  • 3. Pclips installed at correct location and orientation

  • 4. Cable ties tightened at correct tension

  • 5. Torque wrench used at correct torque value

  • 6. Torque value recorded on traveler

PreShipment Verification (CMRUS 100% Inspection)

  • Name Audited

  • 1. Traveler completed

  • 2. Label conforms to drawing

  • 3. All components present

  • 4. All locks engaged and in proper position

  • 5. Witness marks applied

  • 6. PPA conforms to all notes and details

  • 7. Source Release Documentation collected and sent to Cummins

Packaging

  • Name Audited

  • 1. Packaging Standard in Use

  • 2. New packaging (no reused packaging)

  • 3. All connectors protected with bubble wrap

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

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

  • Comments:

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