GM Process / Part Specific Audit

Process Specific Audit: Leak Test Version: 2.0 Issue Date: 15 Sep 2009
Auditor: Supplier: Duns: Date: Location: Part Name:

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

Process Control
Are leak test fixture seals and sensors checked after a predetermined number of rejects? (Alarm limits) Reaction plan when Alarm Limits are reached. Job instructions. Site Procedures / Control Plan. Review logs / Worksheets. Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality) Controls in place (flow-meters, Pressure gages etc.) to ensure appropriate supply of leak test media. Identify drop in pressures.

Is leak testing equipment meeting rated cycle times? Is there a dedicated pneumatic or hydraulic line to conduct the Leak test? Is the line shared by multiple manufacturing lines?

Are leak test employees trained (supervisors, operators, job Monthly reviews and employee sign-off. setters, inspectors, Review employee training records & repairperson etc) ? 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. Site Procedures / Control Plan. Do employees' understand the Observe employee performing tasks job instructions and validate with job instructions. Are machinery, equipment, and Frequency? (Start of shift, mid-shift, gages calibrated / visually prior to change over's and end of shift) inspected? Review logs / Worksheets.

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GM Process / Part Specific Audit

Process Specific Audit: Leak Test Version: 2.0 Issue Date: 15 Sep 2009
Auditor: Supplier: Duns: Date: Location: Part Name:

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

Is there a process to run green and red "master" parts through each leak test operation? Are they certified? Is certification relative to current product and up to date? Does the master part have a defined leakage rate? Are the leakage limits and test method (over/under pressure) agreed with GM Engineering and part of the (Key Product Characteristics) in GM drawings?

Frequency? (Start of shift, mid-shift, prior to change over's and end of shift) Review logs / Worksheets. Review certification records. Compare current product against in-station "masters". Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)

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Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality) Dirt in work-station can interfere with the seals/air-lines etc. Site Procedures / Control Plan. Visually observe workstation and surrounding area. Job Instructions. Visually observe workstation and surrounding area.

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Is operator work area and test function area clean and free of parts and debris? Is proper personal protective gear being utilized by operator? Are scrap parts correctly identified and placed in red scrap bins? Is there a inspection log sheet?

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Site Procedures / Control Plan. Visually observe workstation and surrounding area. Size of filters / change of Filters frequency / Control Plan / PFMEA / Is test media filtered (Air, Fluid, Visual verification. Review PM logs / etc) ? Media Test logs. Is there a process to check chemistry (PH, buffer, media concentration, bacteria etc.) of Job instructions. Site Procedures / test media and where is it Control Plan. Review all logs / 2 of 20 documented? Worksheets.

GM Process / Part Specific Audit

Process Specific Audit: Leak Test Version: 2.0 Issue Date: 15 Sep 2009
Auditor: Supplier: Duns: Date: Location: Part Name:

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

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Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality) Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality) Review site Procedures / Control Plan. Are rust preventive levels within Review all logs / Worksheets. (Maint. control limits? Safety, Process and Quality) Are out-of-specification Review site Procedures / Control Plan. conditions and/or chemical Review all logs / Worksheets. (Maint. adjustments noted? Safety, Process and Quality) How do you treat rejects from leak test? (test them twice again before intro into the process?) If introduced back into the process/value-stream, Review site Procedures / Control Plan. what is the verification & reReview all logs / Worksheets. (Safety, introduction point? Process and Quality) Are any components salvaged from tear-down/re-worked parts? (It is highly recommended to scrap all seals, gaskets, o-rings, valves etc. that function as Leak preventions i.e. One-time use only) Do all re-built parts undergo the same leak-check at the main process line with certified/trained operators? Visual Observation Are there any special handling Review site Procedures / Control Plan. and or cleaning process of re- Review all logs / Worksheets. (Process worked parts required? and Quality) What is the maximum number a Review site Procedures / Control Plan. times a part can be tested Review all logs / Worksheets. (Process before it is scrapped? and Quality) Are rust preventive levels within control limits? Are out-of-specification conditions and/or chemical adjustments noted? 3 of 20

GM Process / Part Specific Audit

Process Specific Audit: Leak Test Version: 2.0 Issue Date: 15 Sep 2009
Auditor: Supplier: Duns: Date: Location: Part Name:

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

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Are all accepted parks marked with a permanent sign or could the marking be removed? Is the leak test done at low & high pressures? Are there requirements for Moisture/Temperature control on the Pressurized Air/Media? Does the leak test machine identify part as part passed, failed and tested? Confirm that fixtures does not clamp componets in a way that would mask a leakage condition. Is there a control of nonconforming process in place to capture rejected/rolled o-rings and lip seals? Are scrap parts correctly identified and removed from area? Is there a recovery process in place to purge system of suspect parts when internal misbuilds or spills occur? Are all quality charts, and supporting documentation current and up to date? Is the final finished part label printing of the label tied back to the Leak test?

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Review site Procedures / Control Plan. Review all logs / Worksheets. (Process and Quality) Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality) Review Engineering documents and contract requirements

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Visual Observation

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Visual Observation

Quality System Basics

Job instructions. Site Procedures / Control Plan. Review logs / Worksheets. Review site Procedures / Control Plan. Review all logs / Worksheets. (Process and Quality) Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality) Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality) Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality) 4 of 20

GM Process / Part Specific Audit

Process Specific Audit: Leak Test Version: 2.0 Issue Date: 15 Sep 2009
Auditor: Supplier: Duns: Date: Location: Part Name:

Assessment Question Number Question Data retention - for traceability / warranty / field action purposes? Does plant management (Production, Quality and Reliability) perform internal layered audits? If not why? Is there a Preventive Maintenance plan on all leak testing equipment (seals / attachment points/ measurement devices, etc.?) Are positive (pressure) and (negative (vacuum) leak checks performed on external connections to leak test stations? (pumps, hoses, etc) Is preventative maintenance on pipes, hoses, and gauges complete? Requirements and Guidance Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality) Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality) Site Procedures / Control Plan. PM plan needs to incorporate the equipment manufacturer recommended regimen. Review PM Log and verify PM is being performed Objective Evidence N/A Satisfactory Not Satisfactory

Preventive Maintenance

Site Procedures / Control Plan. Review PM Log and verify PM is being performed Site Procedures / Control Plan. Review all logs / Worksheets. Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)

Are there scheduled times for tank dumps and cleaning? Are all test equipment parameters reprogrammed after Site Procedures / Control Plan. Review maintenance? all logs / Worksheets. Are leak detection rates (bubble, pressure decay, or helium) established by engineering studies? How are they monitored?

Development
Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality) 5 of 20

GM Process / Part Specific Audit

Process Specific Audit: Leak Test Version: 2.0 Issue Date: 15 Sep 2009
Auditor: Supplier: Duns: Date: Location: Part Name:

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

Are leak test signatures developed using correctly assembled components to determine the characteristics that fall outside of that acceptable assembly signature?

Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality) Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality)

How does the test medium correspond to the serial production used medium? Has supplier established minimum amount of time change when retesting rejected parts? Parts need restablization (i.e. plastic parts)

Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality) Audit Owner: Darnell Alexander

Change History
Date 9/15/2009 9/15/2009 9/15/2009 9/15/2009 Version 1.0 2.0 2.0 2.0 Change Summary

Removed line item 11 from the process section (Is the master part more than 50% of the specification fail limt? (castings or similar parts)cou not receive clarification from engineer who submitted question as he is no longer a employee at General Motors Added line 21 to the process section (Are any components salvaged from tear-down/re-worked parts? ..) Added line 27 to the process section (Does the leak test machine identify part as part passed, failed and tested?) Added line 4 to the process section (Has supplier established minimum amount of time change when retesting rejected parts? Parts need restablization (i.e. plastic parts)

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GM Process / Part Specific Audit

Process Specific Audit: Leak Test Version: 2.0 Issue Date: 15 Sep 2009
Auditor: Supplier: Duns: Date: Location: Part Name:

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

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Specific Audit: Leak Test Issue Date: 15 Sep 2009

Assessment Needs Immediate Action

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Specific Audit: Leak Test Issue Date: 15 Sep 2009

Assessment Needs Immediate Action

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Specific Audit: Leak Test Issue Date: 15 Sep 2009

Assessment Needs Immediate Action

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Specific Audit: Leak Test Issue Date: 15 Sep 2009

Assessment Needs Immediate Action

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Specific Audit: Leak Test Issue Date: 15 Sep 2009

Assessment Needs Immediate Action

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Specific Audit: Leak Test Issue Date: 15 Sep 2009

Assessment Needs Immediate Action

dit Owner: Darnell Alexander Change Summary

Change History

section (Is the master part more than 50% of the specification fail limt? (castings or similar parts)could who submitted question as he is no longer a employee at General Motors

re any components salvaged from tear-down/re-worked parts? ..)

oes the leak test machine identify part as part passed, failed and tested?)

s supplier established minimum amount of time change when retesting rejected parts? Parts need

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Specific Audit: Leak Test Issue Date: 15 Sep 2009

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 #REF! 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

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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! #REF! #REF! #REF! #REF! #REF! #REF!

SUPPLIER ACTION PLAN REPORT

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

Rev. 7 1/7/02

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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.

List of Collaborators
The following provided input or comment in the development of this Process Specific Audit Name Darnell Alexander Steve Stearns Lyndon Lie & EGMs Dan Mandernack & EGMs Steve Williams David Scheper David Gilbert .among others. Approver Shujat Khan Department Author - GPSC - SQ - Suspension SQE SQ Global SMT Manager Product Engineering Product Engineering Global QRD Lead - Steering BFO - Passive Shocks & Struts CI Engineering Manager - Chassis & Powertrain Hardware Region GMNA GMNA GMNA GMNA GMNA GMNA GMNA

SQ Manager Chassis SMT - Suspension & Steering

GMNA

tors

Phone 586-899-5497 586-899-5286 810-730-8729 586-854-9055 248-310-6516 586-889-1502 248-318-1104

email darnell.alexander@gm.com stephan.a.stearns@gm.com lyndon.lie@gm.com daniel.r.mandernack@gm.com steve.williams@gm.com david.c.scheper@gm.com dave.gilbert@gm.com

586-899-5359

shujat.a.khan@gm.com