3.1 ADVANCED PRODUCT QUALITY PLANNING (APQP)
3.1Is there a method to review the following key information prior to building tooling:
3.1.1Drawing Rev level? YES/NO
3.1.2Material grade? YES/NO
3.1.3Relevant specifications listed on purchase order and/or drawing?YES/NO
3.1.4Special requirements and/or any deviation/concession?YES/NO
3.1.5Gauging requirements? YES/NO
3.1.6Finishing requirements?YES/NO
3.1.7New Component Introduction Production Part Approval Process (NCI/PPAP) requirements? YES/NO
3.2Is there a documented procedure to be sure all phases of the NCI/PPAP submission are completed?YES/NO
3.3Are QA personnel trained in NCI/PPAP requirements?YES/NO
3.4Is there a detailed Failure Mode Effect Analysis (FMEA) control plan/process?YES/NO
3.5Is the gating layout calculated and plotted?YES/NO
3.6Has solidification modeling been completed using casting simulation software? YES/NO
If “YES”, what simulation software was used?
4.INCOMING INSPECTION – RAW MATERIAL
4.1Is a procedure in place regarding testing of incoming raw material?YES/NO
4.2Is Scrap Steel inspected prior to accepting the shipment or internal inspection, with regard to the following: YES/NO
4.2.1Visual? YES/NO
4.2.2Chemistry?YES/NO
4.2.3Certificate of inspection?YES/NO
4.2.4Radioactivity?YES/NO NA
Auditor Handbook: NA is applicable for non ferrous materials.
4.3Is Pig Iron inspected prior to accepting the shipment or internal inspection, with regard to the following:
4.3.1Visual? YES/NO
4.3.2Chemistry?YES/NO
4.3.3Certificate of inspection?YES/NO
4.3.4Radioactivity?YES/NO NA
Auditor Handbook: NA is applicable for non ferrous materials.
4.4For alloys purchased to the final chemistry requirements and no additions for the purpose of modifying the melt chemistry are being made, is an initial complete chemistry required? (Subsequent heats only require an alloy type check.)YES/NO NA
4.5Is Alloy inspected prior to accepting the shipment, with regard to the following:
4.5.1Certificate of inspection? YES /NO
4.5.2Chemistry?YES/NO
4.5.3Size?YES/NO NA
4.6Carbon Raiser SECTION NA
4.6.1Is Carbon Raiser inspected prior to accepting the shipment or internal inspection, with regard to the following:YES/NO
Auditor Handbook: If no bake foundry, this does not apply.
4.6.1.1%C? YES/NO
4.6.1.2%S? YES/NO
4.6.1.3Size? YES/NO NA
4.7 Raw Sand
4.7.1Are controlled specifications for the composition and quality assurance of raw sand furnished to each source?YES/NO
4.7.2Is Raw Sand inspected prior to accepting the shipment or internal inspection, including a sieve analysis to determine grain fineness? YES/NO
4.8Bond Pre-Mix SECTION NA
4.8.1Is Bond pre-mix inspected prior to accepting the shipment or internal inspection, with regard to the following:YES/NO
Auditor Handbook: If no bake foundry, this does not apply.
4.8.1.1% Moisture? YES/NO NA
4.8.1.2% Clay? YES/NO NA
4.8.1.3% Loss On Ignition (LOI)? YES/NO NA
4.8.1.4Certificate of inspection? YES/NO
4.9Shell Core Sand SECTION NA
4.9.1Is Shell Core Sand inspected prior to accepting shipment or internal inspection, with regard to the following:YES/NO
4.9.1.1% Resin Content? YES/NO NA
4.9.1.2% LOI? YES/NO NA
4.9.1.3Certificate of inspection?YES/NO
4.10Is the acceptance criteria documented for each raw material? YES/NO
4.11Is there a documented action/reaction plan with “stop points” to follow when nonconforming product is identified? YES/NO
4.12Are raw materials stored in an area adequate to protect the materials from moisture, contamination, oxidation, etc? YES/NO
4.13Are raw materials clearly identified and traceability maintained?