GM Process / Part Specific Audit

Process Specific Audit: Coating Version: 1.0 Issue Date: 24Jun09

Auditor: Supplier: Duns: Date: Location: Part Name:

Assessment Question Number Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory

General
1 Are employees trained (supervisors, operators, job setters, inspectors, repairperson etc) ? Monthly reviews and employee sign-off. Review employee training records & verify employee/management sign-off. Review job instructions. Site Procedures / Control Plan. Review Is there standardized work for worksheets and verify visuals are in each leak test operation? place. Is there a written specific process control plan for all active process? Is there a dedicated and qualified expert on site? Review Process Control Plan and Identify all of the manufacturing steps. (Including cycle time, temperature, etc)

8 9 10

Review plant cleanliness and housekeeping to ensure the work Is work area clean and free of environment is free of contamination. outside elements? (see Contamination Process Audit) Is there an air refreshment and air quality monitoring systems to avoid vapour pollution of the baths? Are there proper protections against hazardous chemical and enviroments? Are all process flowness being managed with PLC control (one piece follow)? Are PM records up to date? Review PM logs and worksheets. Is there a visual check in place to verify material Review customer bar code id, certificate certifications, pack slip, and of analysis and each bin/container. label part numbers? 1 of 16

GM Process / Part Specific Audit

Process Specific Audit: Coating Version: 1.0 Issue Date: 24Jun09

Auditor: Supplier: Duns: Date: Location: Part Name:

Assessment Question Number Question Is there a system in place to review and address customer concerns? Are machinery, equipment, and gages certified? Are GMS principles being used? (Gages marked in optimum range?) What type of test method is utilized? Requirements and Guidance The facility shall document customer concerns along with action plans. Objective Evidence N/A Satisfactory Not Satisfactory

11

12

13

Annual Certification by 3rd Party. Review Certification records. Visually inspect gages. Review requirement for coating thickness, corrosion resistance, adhesion, curing, color, and gloss.

Loading
1 Is there a process in place to Review error proofing process. verify correct parts are loaded? Is there a process in place to ensure part carrying fixtures Review carrying fixture PM. protects unit against damage and/or mutilation? Are conveyors and transmission systems in good form and work properly? well designed and suitable for the parts? Are carrying fixtures stored properly? Is there a process in place to ensure part carrying fixtures provides for adequate coating? Is there a procedure in place for appropriate loading of units? Is the loading process designed for traceability?

6 7

Review drawings and/or specifications to ensure adequate loading angles, directions, and flatness. 2 of 16

GM Process / Part Specific Audit

Process Specific Audit: Coating Version: 1.0 Issue Date: 24Jun09

Auditor: Supplier: Duns: Date: Location: Part Name:

Assessment Question Number Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory

Pre-treatment
1 Is material concentration verified? Review lot numbers, control plans and log sheets. Are temperatures and process times recorded and verified Review temperature gage. per process requirement? Is there a process in place to verify cleaning solutions as Review lot numbers, control plans and suitable for removing all log sheets. process soils as demonstrated by water break? Is there a process in place to ensure adequate pressure/agitation? Is there a process in place to verify cycle time to ensure appropriate exposure to pretreatment? Is corrosion inhibitor concentration regularly checked/inspected? Is there a process in place to verify coating weight, crystal size, and fluoride concentration?

Review control plan, logs and worksheets. Review control plan, logs and worksheets. Review control plan and customer requirement.

What is the dump schedule for Review chemical manufacturer cleaning, rinsing, and sealing? guidelines. Is the temperature in the oildirt removal bath unit under control i.e. within +/-5C and is as required ? 3 of 16

GM Process / Part Specific Audit

Process Specific Audit: Coating Version: 1.0 Issue Date: 24Jun09

Auditor: Supplier: Duns: Date: Location: Part Name:

Assessment Question Number Question Is oil - dirt removal done by basic and acidic bathings and intermediate washings and if necessary manual removal? Is there a final rinse and is it monitored for presence of Review control plan/log sheets. bacteria (for plastic substrate) ? Is there an appropriate process for verifying adequate Review customer specifications. sealing coverage? Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory

10

11

12

Dry Off
1 What is the frequency for air temperature monitoring and control? Is there an appropriate procedure to ensure effective dryness? Are oven set points and process time recorded and verified as meeting the process requirments? Review control plan/log sheets.

Review each lot.

Review control plan/log sheets.

Coating Spray
1 What is the procedure to verify coating is correct and meets compositional requirments? What is the process to monitor gun pressure? What is the process to monitor appropriate coverage of the parts? What is the process to monitor booth humidity? Review customer specifications.

2 3 4

Review PM logs and worksheets. Review Control plan Review control plan and log sheet 4 of 16

GM Process / Part Specific Audit

Process Specific Audit: Coating Version: 1.0 Issue Date: 24Jun09

Auditor: Supplier: Duns: Date: Location: Part Name:

Assessment Question Number 5 6 7 8 9 10 11 Question What is the process to ensure gun functinalities? Is there a process tmonitor / inspect feed hoses for excessive bends and kinks? What is the process to check flow direction? Is there a notification systemm in place in case of system failures? What is the dump schedule for coating? Are filter checked frequently for sizes and type? What is the process to verify paint performance? Requirements and Guidance Review PM logs Review control plan and log sheet Review control plan Review Control plan Review cpntrol plan Review manufacturer recommendations and control plan Review control plan Objective Evidence N/A Satisfactory Not Satisfactory

Cure Oven
1 2 3 4 5 Are oven temperatures, set points, and limits monitored and documented? What is the process to monitor conveyor speed? What is the process to monitor booth temperature and humidity? Is there a process to monitor paint adhesion? Is there a procedure in place to check and maintain proper cure time? Review material specifications Review control plan Review control plan Review control plan and color change requirements Review coating supplier recommendations

Unloading
1 2 What is the process to Review control Plan maintain part racks? Are parts package to minimize Review control Plan mixed parts?

5 of 16

GM Process / Part Specific Audit

Process Specific Audit: Coating Version: 1.0 Issue Date: 24Jun09

Auditor: Supplier: Duns: Date: Location: Part Name:

Assessment Question Number 3 4 Question Is there a re-work procedure in place? Is there a labelling process in place for container identification? Requirements and Guidance Review control Plan Review control Plan Objective Evidence N/A Satisfactory Not Satisfactory

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s Specific Audit: Coating Issue Date: 24Jun09

Assessment Needs Immediate Action

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s Specific Audit: Coating Issue Date: 24Jun09

Assessment Needs Immediate Action

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s Specific Audit: Coating Issue Date: 24Jun09

Assessment Needs Immediate Action

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s Specific Audit: Coating Issue Date: 24Jun09

Assessment Needs Immediate Action

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s Specific Audit: Coating Issue Date: 24Jun09

Assessment Needs Immediate Action

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s Specific Audit: Coating Issue Date: 24Jun09

Assessment Needs Immediate Action

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Process Performance
Supplier Location Duns Commodity Prepared by:

SUPPLIER ACTION PLAN REPORT

Start Date: Rev. Date: Grad Date: Program: SQE SQE Phone & Fax #: Manager: Group: Creativity Team:

Rev. 7 1/7/02

G Y R W B

Green - Task Completed on Time Yellow - Task May Be Late Red - Task is Late White - Task Re-Timed, No Status Blue - Task Status is Incorrect / Not Updated On Track (Bold Box/No Color)
TOTAL

TOTAL 0

STATUS
Oldest Most Recent

ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Priority

Group

ACTION ITEM 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

ACTION LEADER

DATE OPENED

TARGET CLOSE DATE

ACTUAL CLOSE DATE

LAST UPDATE

COUNTER MEASURES

215680469.xlsx.ms_office

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Page 13 of 16

Process Performance
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 #REF! #REF! #REF!

SUPPLIER ACTION PLAN REPORT

0 0 0 0 0 0 0 0 0 0

Rev. 7 1/7/02

0 0 0 0 0 0 0 0 0 0 0 0 0

215680469.xlsx.ms_office

Printed: 3/8/2014

Page 14 of 16

If the question is not applicable then the auditor shall place a check mark in the "N/A" Assessment column.

"Needs Immediate Action" issues shall be addressed prior to the auditor leaving the facility.

If the question is not applicable then the auditor shall place a check mark in the "N/A" Assessment column. If the observed evidence is in compliance to the question then the auditor shall note the evidence in the "Observed Evidence" column and place a check mark in the "Satisfactory" column. If the observed evidence is not in compliance to the question then the auditor shall note the non-compliance evidence in the "Observed Evidence" column and enter into the "Not Satisfactory" column specific actions to address the issue. This information will transfer automatically to the Action Form on the corresponding line number. The auditor shall assign appropriate single point personell and timing to address the issue. When non conforming product is identified during the audit the auditor shall place in the "Needs Immediate Action" column specific actions to address the issue. This information will transfer automatically to the Action form in the same Item No. line. The auditor shall assign appropriate single point personell and timing to address the issue. "Needs Immediate Action" issues shall be addressed prior to the auditor leaving the facility.