Auditor: Date: Score

Supplier: Location: 0%
Duns: Part Name: RED
AUDIT WORKSHEET
QUESTION:
EVIDENCE/
DOCUMENTATION
REQUIRED
QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer
G
Y
R
OBSERVATIONS
1 Raw material inspection.
1.How does supplier verify raw material? Does supplier
use spectro meter?
2.If supplier use spectro meter, Is spectro meter
calibrated before use?
3.Does Master sample available for calibration?
4.Does supplier check hardenability for each lot?.
5.Is Material cert. from steel mill available?
NR NR
2
Mechanical performance test capability for raw
material.
1. Does supplier have capability for mechanical
performance test? Like tensile test
2. Is other mechanical performance test required on
Drawing, SOR? If yes, what it is?
NR NR
3 Forging, if applicable.
1. What is the heating method for raw forging?
2. How does supplier monitor Temperature?
3. How does supplier monitor Start of forging temp.? If
temp is out of control zone, is there any device will alarm?
4. Automatic sorting?
NR NR
4 Are there any gear measuring machine available?
1. CNC gear tester
2. Regular compensation with master
3. Control temperature and moisture of quality lab
4. Operator training
5. Is certificate available? (JIS,DIN )
NR NR
5
Who can perform gear tester ? Any operator or
qualified & trained person.
1. Is training record available?
2. Does this training record is align with the Flexibility
chart?
3. If time permit, pick one parts from final inspection.
Then ask supplier to demonstrate how do they measure a
gear & review the result.
NR NR
6 Is Gear tester calibrated periodically?
1. Pls check calibration report to check previous
calibration date do meet requirement.
2. If calibrate by 3rd party provider, does 3rd party
qualified to perform calibration for gear tester? Any
evidence?
NR NR
7
Does gear tester or CMM are located or setup with
Temp & humidity controlled room? & far from
vibration source.
1. Is daily monitor record for Temp & humidity available.
2. Look around the lab, is there any source of vibration?
Like close to Hydraulic press, runway for Folk lifter..
NR NR
8 Testing fixture for gear analyzer
can the fixturing of the gear assure accuracy? Expanding
mandrel is recommended for a ring gear.
NR NR
9
What kind of gauge does supplier use in
production line? Like for measuring gear width or
thickness...
Is Gauge R&R acceptable? NR NR
10 What is the period for gauge recertified?
1. Any Record to indicate the gauge is recertified.
2. According to the latest certifications record, Is the
record accept or reasonable?
2. What is the data? Is gauge worn to upper limit, lower
limit or out of spec?
NR NR
11
Cutter life management
1.Does the record has identify the life of brand new cutter
& rework cutter life? such as honing stone, cutter..etc
2. Does the machine for gear process have alarm when
cutter life is reach cutter life?
3. If there is no alarm in equipment, how does supplier
control cutter usage? & make sure operator will not use
cutter out of cutter life. ( Pls go to production line to see
how operator doing, also check production record, cutter
life& number of working piece count in machine to see if
it is reasonable)
4. Does supplier has enough back cutter in warehouse for
production? Ask supplier about the lead time for cutter
availability, lead time for cutter rework. In case supplier
will use out of life cutter but cutter is not available.
5. Does supplier has drawing for cutter & order cutter
according this drawing? ( During process develop, new
cutter need to have some trial run to make sure the part
will meet GM drawing spec. if not, the cutter need to be
sent back to cutter supplier to have modification, then trial
run again. Until parts are all meet drawing spec., then
supplier will get cutter drawing from cutter supplier. After
that, cutter will be made according to cutter drawing)
NR NR
Commodity Name - Gear Manufacturing
Version: Initial Release Issue Date: 14 Apr 2011
A. Commodity Control
12
What is the checking frequency for gear profile
related dimension?
1. To have full layout check for gear profile periodically.
To ensure, 100% compliance to Standard not only
drawing.
2. Review drawing carefully to see if there has some
dimension related to gear but not specified in the Gear
information table.
3.What gear related dimension are checking by
production line? What dimension are checking by QC
person? Ensure all dimension checking are covered by
reasonable frequency, qualified person & gauges.
NR NR
13
Are gear profile formed before heat treatment?
1. Is the supplier doing HT test for each batch of raw
material? and correct lead and profile per the test? if not,
how does supplier to adjust process parameter to cover
deformation between lot to lot difference.
2. When does supplier check gear profile if gear profile
are formed before heat Treatment? If supplier check gear
profile before heat treatment, how does supplier make
sure gear profile do meet GM requirement after heat
treatment or in final product?
NR NR
14
Does supplier communicate with GM DRE to make
sure what gear standard will be used if drawing is
not specified. Like JIS, DIN or AGMA...
1. Reference to Each Gear Standard.
Note : Between different standard, same of the
abbreviation may have different meaning or definition. If
there is no full describe in English or only abbreviation,
supplier might have misunderstand on the gear profile.
NR NR
15
Heat treatment Requirements
1. Supplier shall comply with CQI-9.
2. Make sure what the type of heat treatment is required
on drawing. such as Carburizing/Carbonitriding..etc
3. If temper temp specified in Drawing or SOR, make sure
heat treat supplier follow this requirement.
4. Review Hardness & case depth on each zone or
location.
5. Does supplier communicate with GM material Engr for
number of section & location?
6. How does supplier check surface crack after heat
treatment? is it meet GM's requirement or CQI-9.
7. Automized heat treatment cycle control
8. Data banking for traceability
9. Lab and equipment for raw material and heat treated
part
10. Limit sample
11. Shot blasting and peening capability if specified in
part print
NR NR
16 Does part need to have shot peened process?
if yes, must comply with GM 1927-16 shot peen specific
requirements.
NR NR
17
Does drawing or SOR required Major, pitch &
minor diameter must be made simultaneously?
1. Go to shop floor to make sure which minor diameter is
not formed by 2nd operation? Like turning process.
2. Pls also review the control plan & process flow chart
are followed same requirement.
NR NR
18
How does supplier measure run-out for pitch
diameter? If required by drawing.
1. Is GR&R acceptable? A point gage is recommended.
2. Does supplier use gear tester to measure pitch run-out
or use alternative way?
Pls note the datum for measuring pitch run out.
NR NR
19 Rolling test.
1. is the rolling test 100% done?
2. Is the width of the master gear bigger than the tested
parts?
3. Can OD of the master touch out of the active profile to
check extra material?
NR NR
20 Deburr.
1. Deburring method agreed by SQ, DRE?
2. Supplier and GM SQ, DRE agreed on burr size?
NR NR
21
Does the supplier have enough technical expertise
available at the facility?
Looking for the organization chart for gear expert and the
expert for metallurgy .
NR NR
22 The number of gear teeth
The odd and even gear has the difference kind of gear
measurement on some dimension such as tip diameter
,OBD, root diameter.
NR NR
23
Does the gear will be pressed later with shaft by
GM?
For the example Ring gear has to be pressed with the
crank shaft. Ask the supplier for the duplicate press fit on
supplier site and compare the results such as run-out,
gear profile, OBD..etc. before press fit(free state) and
after press fit compare with GM data or they have some
agreement.
NR NR
24
Does the Heat Treater comply with the AIAG CQI-
9 Heat Treat System assessment ?
Completed AIAG CQI-9 Heat Treat System Assessment
annually.
NR NR
25 Does the supplier comply with QSB requirement. Review the QSB score and set the action plan NR NR
26
What the difference of temperature between shop
floor and measurement lab?
The measurement result on the shop floor and the Lab
might difference and does supplier aware of that and how
do they control.
NR NR
27 What is the temperature of the lab? meet the international standard 20+/-2 degree C NR NR
28
The part cool down and same as the lab
temperature before measuring?
Supplier has to wait the parts to cool down to Lab
temperature before measuring.
NR NR
29 What technique for measuring OBD? check the stylus, machine(1 or 2 probe) NR NR
30 What technique for measuring root Diameter? check the size of stylus, machine(1 or 2 probe) NR NR
31 What technique for measuring run out? by Gear tester/runout tester..etc. NR NR
32 Does supplier has the functional test on site?
Functional test is the very accuracy for the run-out test.
Review the master gear to mesh with the tested gear is
approved by GM?
NR NR
33 What technique for measuring pitch diameter? by Gear tester. NR NR
34
Does supplier know how to calculate the tooth
bias?
Some case GM will need the reference for tooth bias. NR NR
35 Have supplier done Gauge R&R? Review the Gauge R&R and set action plan. NR NR
36
Have supplier discussed with GM DRE for the start
of check and end of check on the involutes?
review that supplier has the agreement with the GM DRE.
Sometimes the method is difference such as cut 10% or
5%, also review the drawing.
NR NR
37
Does supplier has the process capability to
review?
review process capability. NR NR
38
Does supplier has the record for the percent of
distortion before and after heat treated?
review process the percentage. NR NR
39
Does supplier has the mapping result for the
hardness?
review the hardness at the difference location on the
loading pattern on heat treatment process.
NR NR
40
How supplier identify the gear that going to has
the hardness check(heat treat)?
Some supplier will use the bad part put in the loading
pattern for heat treat and use this part for hardness
check. Review how they control the part mix and do they
destroy the part before heat treatment?
NR NR
41 Furnace loading and loading pattern
check the lay out of the gears on loading pattern. Once
established the heat treat parameters should no change.
IF the incorrect material is used to make the gears it will
behave differently and could possibly give you non
conforming parts for hardness and unacceptable
distortion.
NR NR
42
Furnace Temperature ? Quench Oil Temperature?
Tempering Furnace Temperature & Quench Oil
agitation
Ask if the material match with metallurgy book. Once
established the heat treat parameters should no change.
IF the incorrect material is used to make the gears it will
behave differently and could possibly give you non
conforming parts for hardness and unacceptable
distortion.
NR NR
43
Proper gear micro geometry control of Gear
Shaving process
1. Tool sharpening and inspection equipments
2. Setup approval from line leader or quality control
3. CNC controlled axes
NR NR
44
Proper gear micro geometry control of Gear
Hobbing process
1. Tool sharpening and inspection equipments
2. Setup approval from line leader or quality control
3. CNC controlled axes
NR NR
45 Gear Rolling test
1. Automatic sorting of OBD, runout and nick by master
gear
2. Data banking for traceability
3. Automatic calculation of Cp and CpK
4. Regular calibration with master and monitor gear
5. Automatic sorting of Good, NG and Nick parts
6. Automatic Marking on Nick area
NR NR
46 Jig fixture run-out check
Supplier to have the jig fixture runout check every
shift(can be checked by master ring)
NR NR
AUDIT WORKSHEET
QUESTION:
EVIDENCE /
DOCUMENTATION
REQUIRED
QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer
G
Y
R
OBSERVATIONS
1 NR NR
2 NR NR
3 NR NR
4 NR NR

Rating:
Green 90% / Yellow 70-89% / Red 69%
Sections Percent of compliance Results
A. Commodity Control 0% RED
B. Development 0% RED
SCORE
B. Development
If any of the single sections is rated RED, overal audit result is RED with 0% score
Summary score 0% RED Pts Element Scoring
0
Requirements not met, needs immediate correction
SQE to assure actions are in place prior to leaving the facility,
including CS1/2 implementation if necessary
1
Requirements not met, process acceptable with additional controls in
place
2 Requirements met, process has improvement potential
3 Requirements fully met, best practice process in place
NA Not Applicable (does not impact audit score)
GM Representative Name with Signature NR Not Rated (impacts audit score)
Supplier Representative Name with Signature
Process Performance
SUPPLIER ACTION PLAN REPORT
Rev. 7 1/7/02
Supplier Start Date:
Location Rev. Date:
Duns Grad Date:
Commodity Program:
Prepared by:
G Green - Task Completed on Time
Y Yellow - Task May Be Late
R Red - Task is Late
W White - Task Re-Timed, No Status
B Blue - Task Status is Incorrect / Not Updated
On Track (Bold Box/No Color)
ITEM
AUDIT
SECTION
Priority ACTION ITEM ACTION LEADER
DATE
OPENED
TARGET
CLOSE DATE
ACTUAL
CLOSE DATE
LAST
UPDATE
1 2 3 4 5 6 COUNTER MEASURES
1
2
3
4
5
6
7
8
9
10
STATUS
Creativity Team:
SQE
SQE Phone:
Manager:
Group:
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235057580.xlsx.ms_office Printed: 6/20/2014 Page 5 of 5