Process Audit GM Process / Part Specific AuditProcess Specific Audit: Leak TestVersion: 2.0 Issue Date: 15 Sep 2009Auditor:Date:Supplier:Location:Duns:Part Name:AssessmentQuestion NumberQuestionRequirements and GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionProcess Control1Are leak test fixture seals and sensors checked after a pre-determined number of rejects? (Alarm limits)Reaction plan when Alarm Limits are reached. Job instructions. Site Procedures / Control Plan. Review logs / Worksheets.2Is leak testing equipment meeting rated cycle times?Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality)3Is there a dedicated pneumatic or hydraulic line to conduct the Leak test? Is the line shared by multiple manufacturing lines?Controls in place (flow-meters, Pressure gages etc.) to ensure appropriate supply of leak test media. Identify drop in pressures.4Are leak test employees trained (supervisors, operators, job setters, inspectors, repairperson etc) ?Monthly reviews and employee sign-off. Review employee training records & verify employee/management sign-off5Is there standardized work for each leak test operation?Review job instructions. Site Procedures / Control Plan. Review worksheets and verify visuals are in place.6Do employees' understand the job instructionsSite Procedures / Control Plan. Observe employee performing tasks and validate with job instructions.7Are machinery, equipment, and gages calibrated / visually inspected?Frequency? (Start of shift, mid-shift, prior to change over's and end of shift) Review logs / Worksheets.8Is 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?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".9Does the master part have a defined leakage rate?Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)10Are the leakage limits and test method (over/under pressure) agreed with GM Engineering and part of the (Key Product Characteristics) in GM drawings?Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality)11Is operator work area and test function area clean and free of parts and debris?Dirt in work-station can interfere with the seals/air-lines etc. Site Procedures / Control Plan. Visually observe workstation and surrounding area.12Is proper personal protective gear being utilized by operator?Job Instructions. Visually observe workstation and surrounding area.13Are scrap parts correctly identified and placed in red scrap bins? Is there a inspection log sheet?Site Procedures / Control Plan. Visually observe workstation and surrounding area.14Is test media filtered (Air, Fluid, etc) ?Size of filters / change of Filters frequency / Control Plan / PFMEA / Visual verification. Review PM logs / Media Test logs.15Is there a process to check chemistry (PH, buffer, media concentration, bacteria etc.) of test media and where is it documented?Job instructions. Site Procedures / Control Plan. Review all logs / Worksheets.16Are rust preventive levels within control limits?Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)17Are out-of-specification conditions and/or chemical adjustments noted?Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)18Are rust preventive levels within control limits?Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)19Are out-of-specification conditions and/or chemical adjustments noted?Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)20How do you treat rejects from leak test? (test them twice again before intro into the process?) If introduced back into the process/value-stream, what is the verification & re-introduction point?Review site Procedures / Control Plan. Review all logs / Worksheets. (Safety, Process and Quality)21Are 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 Observation22Are there any special handling and or cleaning process of re-worked parts required?Review site Procedures / Control Plan. Review all logs / Worksheets. (Process and Quality)23What is the maximum number a times a part can be tested before it is scrapped?Review site Procedures / Control Plan. Review all logs / Worksheets. (Process and Quality)24Are all accepted parks marked with a permanent sign or could the marking be removed?Review site Procedures / Control Plan. Review all logs / Worksheets. (Process and Quality)25Is the leak test done at low & high pressures?Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality)26Are there requirements for Moisture/Temperature control on the Pressurized Air/Media?Review Engineering documents and contract requirements27Does the leak test machine identify part as part passed, failed and tested?Visual Observation28Confirm that fixtures does not clamp componets in a way that would mask a leakage condition.Visual ObservationQuality System Basics1Is there a control of non-conforming process in place to capture rejected/rolled o-rings and lip seals?Job instructions. Site Procedures / Control Plan. Review logs / Worksheets.2Are scrap parts correctly identified and removed from area?Review site Procedures / Control Plan. Review all logs / Worksheets. (Process and Quality)3Is there a recovery process in place to purge system of suspect parts when internal misbuilds or spills occur?Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)4Are all quality charts, and supporting documentation current and up to date?Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality)5Is the final finished part label - printing of the label tied back to the Leak test?Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality)6Data retention - for traceability / warranty / field action purposes?Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality)7Does plant management (Production, Quality and Reliability) perform internal layered audits? If not why?Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)Preventive Maintenance1Is there a Preventive Maintenance plan on all leak testing equipment (seals / attachment points/ measurement devices, etc.?)Site Procedures / Control Plan. PM plan needs to incorporate the equipment manufacturer recommended regimen. Review PM Log and verify PM is being performed2Are positive (pressure) and (negative (vacuum) leak checks performed on external connections to leak test stations? (pumps, hoses, etc)Site Procedures / Control Plan. Review PM Log and verify PM is being performed3Is preventative maintenance on pipes, hoses, and gauges complete?Site Procedures / Control Plan. Review all logs / Worksheets.4Are there scheduled times for tank dumps and cleaning?Review site Procedures / Control Plan. Review all logs / Worksheets. (Maint. Safety, Process and Quality)5Are all test equipment parameters reprogrammed after maintenance?Site Procedures / Control Plan. Review all logs / Worksheets.Development1Are leak detection rates (bubble, pressure decay, or helium) established by engineering studies? How are they monitored?Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality)2Are 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)3How does the test medium correspond to the serial production used medium?Review Engineering documents and contract requirements. Site Procedures / Control Plan. Review logs / Worksheets. (Process and Quality)4Has 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 AlexanderChange HistoryDateVersionChange Summary9/15/091.0Removed line item 11 from the process section (Is the master part more than 50% of the specification fail limt? (castings or similar parts)could not receive clarification from engineer who submitted question as he is no longer a employee at General Motors9/15/092.0Added line 21 to the process section (Are any components salvaged from tear-down/re-worked parts? ..)9/15/092.0Added line 27 to the process section (Does the leak test machine identify part as part passed, failed and tested?)9/15/092.0Added 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)

&C&P of &NList actual observations from the suppliers shop floor."Needs Immediate Action" issues shall be addressed prior to the auditor leaving the facility.If the observed evidence is not in compliance to the Requirements and Guidance 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.

Action FormSupplierStart Date:SQELocationRev. Date:SQE Phone & Fax #:DunsGrad Date:Manager:CommodityProgram:Group:Prepared by:Creativity Team:GGreen - Task Completed on TimeYYellow - Task May Be LateRRed - Task is LateWWhite - Task Re-Timed, No StatusBBlue - Task Status is Incorrect / Not UpdatedOn Track (Bold Box/No Color)TOTALTOTALSTATUS00ITEMPriorityGroupACTION ITEMACTION LEADERDATE OPENEDTARGET CLOSE DATEACTUAL CLOSE DATELAST UPDATE123456COUNTER MEASURES102030405060708090100110120130140150160170180190200210220230240250260270280290300310320330340350360370380390400410420430440450460470480490500510520530540

&L&"Tahoma,Italic"&EProcess Performance&C&"Arial,Bold"&16SUPPLIER ACTION PLAN REPORT&R&7Rev. 7 1/7/02&L&F&CPrinted: &D&RPage &P of &NOldestMost RecentCOUNTER MEASURES:LAST UPDATE: The date the SQE reviewed the action item.ACTUALCLOSE DATE: The date the action item was closed TO INCLUDE VALIDATION.

The SQE should validate the action item as being closed and RESOLVED.TARGET CLOSE DATE: The date the supplier will complete the action item.

This date may change. If the date changes, you are required to entry the correct color code in the pass status and present status columns. A comment on why the change to be entered in the comment fieldSTART DATE: The date the action item was identified and listed in the action item columnACTION LEADER: The person that leads the team to make the improvements. This should be the suppliers person but may be a GM Management person.ACTION ITEM: The item that requires action to improve the process or quality of the product being produced.Group / Clasification1- Normal priority

2- High priority

3- Highest priorityFormula: DO NOT TYPE IN THIS CELL, UNLESS YOUR ARE MODIFYING THE FORMULAFormula: DO NOT TYPE IN THIS CELL, UNLESS YOUR ARE MODIFYING THE FORMULAPAST STATUS: The cell is filled in when the status changes. Oldest status to the leftIf status is WHITE put a "W" in the cell. Do not leave blank.Copy the cell for the correct color.

COLOR CODE:GREEN: Task Completed on Time YELLOW: Action item is in trouble and may affect target date.RED: Action item has missed target date.WHITE: Task Re-Timed, No StatusBLUE: Task Status is incorrect / Not UpdatedPerson at supplier that prepared the form for the GM SQE. (If applicable)For PDC SQE Only:Identify which program your supplier is in "IQ' or "SQA".Graduation Date:This Date Will Be Determined By GM SQ Directors

InstructionIf 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.

ColloboratorsList of CollaboratorsThe following provided input or comment in the development of this Process Specific AuditNameDepartmentRegionPhoneemailDarnell AlexanderAuthor - GPSC - SQ - Suspension SQEGMNA586-899-5497darnell.alexander@gm.comSteve StearnsSQ Global SMT ManagerGMNA586-899-5286stephan.a.stearns@gm.comLyndon Lie & EGMsProduct EngineeringGMNA810-730-8729lyndon.lie@gm.comDan Mandernack & EGMsProduct EngineeringGMNA586-854-9055daniel.r.mandernack@gm.comSteve WilliamsGlobal QRD Lead - SteeringGMNA248-310-6516steve.williams@gm.comDavid ScheperBFO - Passive Shocks & StrutsGMNA586-889-1502david.c.scheper@gm.comDavid GilbertCI Engineering Manager - Chassis & Powertrain HardwareGMNA248-318-1104dave.gilbert@gm.com.among others.ApproverShujat KhanSQ Manager Chassis SMT - Suspension & SteeringGMNA586-899-5359shujat.a.khan@gm.com

stephan.a.stearns@gm.comlyndon.lie@gm.comdaniel.r.mandernack@gm.comsteve.williams@gm.comdavid.c.scheper@gm.comdave.gilbert@gm.comshujat.a.khan@gm.comdarnell.alexander@gm.com