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Incoming Check Sheet Form - Excel by sbn59102

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Incoming Check Sheet Form document sample

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									QAV Date:
Supplier Name:
Parts Evaluated:
Project:
Type of Casting: Circle One:   Tilt     Gravity       LPDC       HPDC   Ferrous

                                    Type of Casting MPR applies to:
 1   Receiving Inspection        Tilt  Gravity LPDC HPDC Ferrous

 1                                X       X       X          X     X


 2                                X       X       X          X     X


 2         Melting Furnace       Tilt   Gravity LPDC    HPDC Ferrous

 1                                X       X       X          X     X
 2                                X       X       X          X     X


 3        Holding Furnace        Tilt   Gravity LPDC    HPDC Ferrous

 1                                X       X       X          X     X


 2                                X       X       X          X     X
 3                                X       X       X          X     X


 4           Degassing           Tilt   Gravity LPDC    HPDC Ferrous
 1                                X       X       X          X     X
 2                                X       X       X          X     X
 3                                X       X       X          X     X
5      Sand Core       Tilt   Gravity LPDC   HPDC Ferrous

1                      X               X             X


6       Molding        Tilt   Gravity LPDC   HPDC Ferrous
1                      X               X             X

2                      X               X             X


7       Pouring        Tilt   Gravity LPDC   HPDC Ferrous

1                      X        X      X      X      X
2                      X        X      X      X      X
3                      X        X      X      X      X


8         Die          Tilt   Gravity LPDC   HPDC Ferrous


1                      X        X      X      X      X

2                      X        X      X      X      X
3                      X        X      X      X      X

4                      X        X      X      X      X

5                      X        X      X      X      X


    Shot Blast/Flash
9   Removal/Trim Die   Tilt   Gravity LPDC   HPDC Ferrous

1                      X        X      X      X      X
2                      X        X      X      X      X
10   Quality   Tilt   Gravity LPDC   HPDC Ferrous

1              X        X      X      X      X
2              X        X      X      X      X
3              X        X      X      X      X
4              X        X      X      X      X
5              X        X      X      X      X
6              X        X      X      X      X
7              X        X      X      X      X
                                                              CASTING MINIMUM PROCESS R



HPDC      Ferrous


                            Item

       Is the correct part Raw Material being Received?



       Must control Raw Material being loaded into furnace




                            Item

       How is the molten material temperature controlled and verified?

       Re-melt percentage must be controlled.




                            Item


       How is the molten material temperature controlled and verified?



       Must control casting material temperature before entering mold.
       Must verify correct material properties.




                            Item
       Must control machine settings

       Must confirm correct gas being used.
       Must confirm gas content after degassing.
                     Item

Must confirm sand properties




                     Item
Must confirm mold machine and die alignment


Must control parameters of mold machine




                       Item
Must control mold filling speed, pressure curve, curing time, die
clamp pressure
Must control inoculation amount/nodularity

Must control die temperature/die flame and cooling rate.




                     Item



Must confirm die dimensions.


Must have documented die maintenance and repair.
Must have model type and cavity number on die.


Must confirm die lube.


Must confirm die coating.




                     Item


Must confirm shot size and type
Must control load size, time and shot speed/pressure for flash
removal equipment.
                     Item
Must have material checks to verify hardness and chemistry
(Ferrous and Aluminum castings)
Must complete visual casting defect checks

Must perform a casting dimension check.

Must perform a core dimension check.

Must perform mechanical properties testing.
Must have capability and perform destruct testing. (porosity, color,
etc..)
Must have capability and perform non-destruct testing.
CASTING MINIMUM PROCESS REQUIREMENTS
                                               LEGEND:

                                                                     .
                                                                     X


                     Check Method                           Is this controlled in
                      Suggestion                           current process Y/N

    Received and confirm properties of incoming raw
    material. Information must be documented.
    Must record all raw material loaded into each
    furnace, by furnace identification: Must record: Lot
    number, Date, Time, Bundle, or Heat number,
    Supplier name



                     Check Method                           Is this controlled in
                      Suggestion                           current process Y/N
    Pyrometer/Thermocouple/Control panel. Document
    temperature of material.

    % of scrap per SOP (Standard Operating Procedure)



                     Check Method                           Is this controlled in
                      Suggestion                           current process Y/N

    Received and confirm properties of incoming raw
    material. Information must be documented.

    Chart recorder/PLC interlock and/or manually
    recorded. When temperature is out of specification
    prior to pouring, must have immediate alert.
    Per Specification.



                     Check Method                           Is this controlled in
                      Suggestion                           current process Y/N
    Check Sheet

    Certification sheets from supplier
    Vacuum fusion analysis or equivalent


                     Check Method                           Is this controlled in
                                                           current process Y/N
                                                     Is this controlled in
                    Suggestion                      current process Y/N

Certification sheets from supplier



                Check Method                         Is this controlled in
                 Suggestion                         current process Y/N
Height gauge, dial indicators, alignment fixtures


Gauges on machine/check sheet



                Check Method                         Is this controlled in
                 Suggestion                         current process Y/N

PCL
Per specification

PLC / Flow gauge / Temperature controller



                Check Method                         Is this controlled in
                 Suggestion                         current process Y/N



Die maker data, Measure parts off die


PM schedule / Signed off completed work order
Setup check sheet / part confirmation


Lube ratio and application pattern


Thickness check gauge / SOP



                Check Method
                                                     Is this controlled in
                                                    current process Y/N
                    Suggestion

Incoming receiving inspection

PLC, pressure gauge


                Check Method                         Is this controlled in
                                                    current process Y/N
                                                   Is this controlled in
                    Suggestion                    current process Y/N
Brinnell Test, SEM, Test lab, Spectrometer, and
Rockwell
Visual/Magnaflux

CMM, QC gauges

CMM, QC gauges

Tensile tester

Per specification
X-ray, Eddy current, Magnaflux, etc..
REQUIREMENTS
            Procedure followed. Hard/Soft-side item functioning. OK for MP.
          Procedure utilized, but improved compliance required. Low risk to MP
      Procedure not followed. Immediate countermeasure required, must fix for MP.



                                                                          JUDGMENT
            Method of control                      Frequency                        X

                                                   Each Heat or Lot


                                                   Each bundle or
                                                   charge



                                                                          JUDGMENT
            Method of control                      Frequency                        X

                                                   Each Heat or Lot
                                                   Continuous or each
                                                   heat



                                                                          JUDGMENT
            Method of control                      Frequency                        X

                                                   Continuous




                                                   Each Heat or Lot
                                                   Each Heat or lot.



                                                                          JUDGMENT
            Method of control                      Frequency                        X
                                                   Once per day
                                                   Per lot of gas
                                                   received.
                                                   Per heat


                                                                          JUDGMENT
Method of control   Frequency                   X
                    Per lot of sand
                    received



                                         JUDGMENT
Method of control   Frequency                   X
                    Per PM schedule
                    New Model
                    launch/Setup/Once
                    per shift



                                         JUDGMENT
Method of control   Frequency                   X
                    Continuous or
                    check sheet
                    Per batch
                    Continuous or
                    check sheet



                                         JUDGMENT
Method of control   Frequency                   X
                    New Model launch
                    and when a new
                    die is issued.
                    Per supplier PM
                    schedule / As
                    needed
                    At model change
                    Per certification
                    sheet / At mix
                    timing / At setup
                    Per supplier PM
                    schedule / As
                    needed



                                         JUDGMENT

Method of control   Frequency                   X
                    New Model launch /
                    Once per lot

                    Shift Start up


                                         JUDGMENT
Method of control   Frequency             X

                    Per batch
                    Continuous
                    At die set and once
                    per shift
                    At die set and once
                    per shift

                    New Model launch

                    As required
                    As required
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