Walter G Dockett

Audit Process- WeldingSUPPLIER INFORMATION

CompanyAddressSurvey Personnel (EPC)

Turn ScrewAnywhere USA (Op Man.)

(QAM)

(Man. Eng.)

(Man. Sup.)

Business Characterization:Established In:No. of Employees:Facility Size (ft2):No. of Shifts:Shift Length (hrs.):

No. of QA Personnel:No. of Weld Inspectors:CWI qualified (Y/N):Government Agency On-Site (Y/N):

No. of ASNT Level I/II/III NDT Inspectors:No. of NAS-410 NDT Inspectors:

No. of Welders:No. of Welding Supervisors:No. of Welding Eng.:No. of Mfg. Eng.:

Quality Systems Approvals (e.g., ISO, AS9100, NADCAP):NDT Methods Employed:

PLEASE ANSWER: Y (YES) N (NO) or NA (NOT APPLICABLE)Organization and ReviewYNN/A

Is there separation in reporting responsibilities for personnel responsible for quality control?

Does the Quality Control Inspector have the authority to Stop Work and the responsibility to identify quality problems and provide recommendations?

Is there objective evidence of a review process of material test reports to ASTM specifications. Note: If CMTRs are not required by contract documents, the welding fabricator must show the capability of reviewing the CMTRs?

Are materials and items identified and traceable as specified in the TDP and Quality Program Receiving and Manufacturing operations?

Do Purchase Orders for filler materials specify the American Welding Society Classification and Specification?

COMMENTS/RECOMMENDATIONS: ______________________________________________________________________________________________________________________________________________________________________________

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Auditors SIGNATURE: _____________________________ DATE: ___________________________

PLEASE ANSWER: Y (YES) N (NO) or NA (NOT APPLICABLE)Reference Library - ALL REFERENCE MATERIAL SHALL BE TO THE LASTEST PUBLISHED VERSION OR REVISION.YNN/A

Aluminum Design Manual from the Aluminum Association

AMS-STD-1595 (Qualification of Aircraft, Missile & Aerospace Fusion Welders)

ANSI Z49.1 (Safety in Welding, Cutting, and Allied Processes)

ASME Boiler and Pressure Vessel Code, Section V: Nondestructive Examination

ASTM E1444 (Standard Practice for Magnetic Particle Testing)

ASTM E1417 (Standard Practice for Liquid Penetrant Testing)

ASTM E1742 (Standard Practice for Radiographic Examination)

ASTM E164 (Standard Practice for Ultrasonic Testing)

ASTM E1648-95 (Standard Reference Radiographs for Examination of Aluminum Fusion Welds)

AWSB1.11 (Guide for the Visual Examination of Welds)

AWS A3.0 (Standard Welding terms and Definitions)

AWS B2.1 (Specification for Welding Procedure and Performance Qualification)

AWS B2.2 (Standard for Brazing Procedure and Performance Qualification)

AWS B4.0 (Standard Methods For Mechanical Testing Of Welds)

AWS D1.1 (Structural Welding Code Steel)

AWS D1.2 (Structural Welding Code Aluminum)

AWS D1.3 (Structural Welding Code Sheet Steel)

AWS D1.6 (Structural Welding Code Stainless Steel)

AWS D1.9 (Structural Welding Code Titanium)

AWS D9.1 (Sheet Metal Welding Code)

AWS D17.1 (Specification for Fusion Welding for Aerospace Applications)

AWS D17.2 (Specification for Resistance Welding for Aerospace Applications)

AWS A2.4 (Standard Symbols for Welding, Brazing and Nondestructive Examination)

MIL-STD-2219 (Fusion Welding for Aerospace Applications)

MIL-STD-271 (Requirements for Non-Destructive Testing Methods)

MIL-STD-2035 (Nondestructive Testing Acceptance Criteria)

MIL-W-6858 (Welding, Resistance: Spot and Seam)

NADCAP welding documents (e.g., SAE AS 7110, NADCAP Requirements for Welding/Brazing)

NADCAP NDT inspection documents

NAVSEA Welding Standard 250-1500-1

NAVSEA Technical Publication S9074-AQ-GIB-010/248

NAVSEA Technical Publication S9074-AR-GIB-010/278

NAS-410 (Certification & Qualification of Nondestructive Test Personnel)

WS 33739 (Raytheon Process Specification for Aerospace Fusion Welding)

Certifications

Non-Destructive Testing MethodsYNN/A

Radiographic Inspection (RT)

Ultrasonic Inspection (UT)

Magnetic Particle (MT)

Penetrant Inspection (PT)

Visual Inspection (VT)

Qualification Specification

ASTM E164

ASTM E1417

ASTM E1444

ASTM E1742

AWS QC1

PLEASE ANSWER: Y (YES) N (NO) or NA (NOT APPLICABLE)Identify percentage Welding / Brazing / Cutting Processes Employed By the Auditee.

Weld Process%Weld Process%Weld Process%Cutting Process%

GTAW30SW0LBW0OFC0

GMAW70FSW0ESD/ESA0PAC0

PAW0FRW0Other: 0LBC0

FCAW0RSW0Torch Brazing0Water Jet0

SMAW0RSEW0Dip Brazing0CAC-A0

SAW0EBW0Vacuum Brazing0Other:

PLEASE ANSWER: Y (YES) N (NO) or NA (NOT APPLICABLE)Health and SafetyYNN/A

Is there an EH&S (Environmental Health & Safety) officer, or an Industrial Hygienist on-site?

Is there objective evidence of a Welding Safety Program?

Is there objective evidence of safety training classes being conducted?

Is the facility environmentally controlled (i.e., fully heated and air conditioned)?

Is the relative humidity monitored and documented within the facility/welding environment?

Are the oxygen levels monitored within the facility argon gas distribution system continuously?

Is there a facilities Equipment List/capabilities profile sheet available?

Does the facility have lifting crane capacity within the welding area?(Explain in detail)

What type of lifting crane? Monorail? Gantry? Cantilever/Jib?

Does the facility employ welding positioners?(Explain in detail)

Is there a designated area for weld/base material grinding?

Is the welding/fabrication area safe, clean and orderly?

Is ventilation equipment is employed for welding fume extraction?

Are Pre and Post-weld heat treatments (PWHT) performed at your facility?

Is there a separate area for stainless steel, titanium, carbon steel or aluminum material welding?

Is blast cleaning performed within your facility?

Is there a materials laboratory on-site for weld metal and base metal analysis?

Does the organization perform leak testing?

What type of process: Helium? Freon? Hydrostatic? Air Pressure/Bubble?

Is there objective evidence of weld operator annual visual exams?

Is there objective evidence of weld inspectors annual visual exams?

COMMENTS/RECOMMENDATIONS: ______________________________________________________________________________________________________________________________________________________________________________

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Auditors SIGNATURE: _____________________________ DATE: ___________________________

PLEASE ANSWER: Y (YES) N (NO) or NA (NOT APPLICABLE)Quality Control - DocumentationYNN/A

Does the Organization have a Quality Manual?

Are sub-tier suppliers qualified by a documented evaluation?

Do purchase orders for filler materials specify the AWS Classification and Specification?

In the event the applicant purchases weld wire, steel material, paint, etc., are the manufacturer's test reports or certificates of compliance on file at the location where the material is being utilized?

Have controls been established to monitor the receipt of incoming material?

Is a quality control program in effect to allow management to assess whether work is being performed according to specification?(Explain in detail)

Is there objective evidence of correction to non-conforming material or work in process?

Are weldments traceable to a qualified welder?

Is a continuity log maintained to document that a welder/welding operator has welded with a particular process, material type & weld joint geometry within the last 6 months?

Is there a formal Material Review Board (MRB) established for disposition of unsatisfactory/unacceptable weldments?

Are weld defects dispositioned and signed off by qualified personnel?

Is there objective evidence to ensure that welds are not obstructed by subsequent operations and are inspected prior to being covered up (e.g., witness/inspection hold points)?

Are requests for information necessary to resolve discrepancies and variations from contract requirements documented?

Is there a procedure at the job site for processing revised and voided drawings?

COMMENTS/RECOMMENDATIONS: _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Auditors SIGNATURE: ___________________________________ DATE: ____________________

Quality Control Filler MetalsYNN/A

Are sub-mergered arc welding (SAW) fluxes and SAW welding filler wire properly identified?

Is SAW welding filler wire and SAW fluxes stored in a clean, secure & dry environment? (i.e. Ovens)?

Are there established procedures for the proper storage and control of low hydrogen SMAW electrodes? Ovens?

Are filler materials stored as required by the manufacturers recommendations?

If low hydrogen filler metal is used, is the environment within the storage oven measured?

Are welding filler metal traceable to a CMTR?

Is the welding filler wire HT # and Lot # documented on the Traveler/Router (if required by the Contract Specifications)?

Does the welding filler wire meet the Contract Specifications?

Is welding filler wire sent to an independent material's lab for testing and P.O. verification prior to being employed?

Is weld filler wire distribution Controlled?

Are used weld filler wire disposed of After welding activities (e.g., stub-end box)?

Is cladding performed? Hard surfacing/Hard facing?

COMMENTS/RECOMMENDATIONS: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Auditors SIGNATURE: ___________________________________ DATE: ____________________

PLEASE ANSWER: Y (YES) N (NO) or NA (NOT APPLICABLE)Quality Control Welding OperationYNN/A

Procedure Qualification Records (PQR's) and Welding Procedure Specifications (WPS's) are qualified in accordance with what Code? Circle code(s): B2.1, D1.1; D1.2, D1.3; D1.6; D9.1; D17.1; D17.2; IX; NAVSEA; MIL-W- 6858.

What position(s) are welders qualified in? Circle position(s): Plate: 1G, 1F; 2G, 2F; 3G, 3F; 4G, 4F. Pipe: 1G, 1F; 2G, 2F; 4F; 5G, 5F; 6G, 6GR

Has the Organization engaged in DOD/Military (MIL-STD) welding activities prior to this Audit?

What is the percentage of commercial and military welding activities (% total must equal 100)?(Explain in detail)

Is there objective evidence of surface condition and cleanliness of the weld joint faying surfaces and filler metal examined just prior to welding?

Are Pre-weld, Interpass and Post-weld cleaning requirements defined within the WPS?

Are Preheat, Interpass and Post-weld heat-treatments addressed within the WPS?

Are flux and rod ovens adequate and close enough to where the work is being performed and are they operating per the latest AWS requirements?

For automatic/mechanized welding (as defined in AWS A3.0), are the weld settings used in production within range of those documented on the WPS or PQR?

Are welding gases traceable to a CMTR?

If the Organization mixes their own shielding gases are Calibrated Mixture Chambers Used?

Are O2 level verified within a purge gas/weldment environment?

If the Organization uses a weld chamber are O2 analyzer Installed?

Is there an established calibration program for calibrating all individual welding power supplies, panel ammeters, panel voltmeters, wire feeders, positioners, etc.?

Is there an established preventive maintenance program for welding equipment?

How are weld/weldment temperatures (i.e., preheat, interpass, post-weld) monitored? Circle Selection(s):Surface contacting pyrometer? Temperature crayons, liquid, pellets, stickers?

Non-surface contacting technology (e.g., IR heat sensor)?

COMMENTS/RECOMMENDATIONS:_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Auditors SIGNATURE: ___________________________________ DATE: ____________________

PLEASE ANSWER: Y (YES) N (NO) or NA (NOT APPLICABLE)Quality Control - Weld InspectionYNN/A

Are weld inspectors qualified and knowledgeable with the specifications, which apply to the fabricators work? If an AWS Certified Welding Inspector is not available, documentation of the inspectors knowledge is required?

Are written welding procedures (signed by the responsible company representative) in close proximity to and used by the welders?

Do you have objective evidence that Welding Inspectors meet the requirements of Raytheon's WS 33739?

Are tools or aids used for visual weld inspection?

Are MSDS available to the workers?

Are borescopes, fiberscopes or videoscopes employed for visual weld inspection?

Is there objective evidence of visual (VT) weld inspections being performed Before, During and After additional stress inducing operations (e.g., straightening/plastic deformation, heat-treatment) have been accomplished?

Are there Hold Points at the facility strictly devoted to weld inspection?

Are nondestructive examination personnel qualified to the Scope of Work and qualification records kept in accordance with the American Society of Nondestructive Testing (ASNT) and/or NAS-410?

Is there a formal Material Review Board (MRB) established for disposition of unsatisfactory/unacceptable weldments?

COMMENTS/RECOMMENDATIONS: ________________________________________________________________________________________________________________________________________________________________

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Auditors SIGNATURE: ___________________________________ DATE: ____________________________

PHONE (123) 456-7890 FAX (123) 456-7890 EMAIL- info@.com___________________________________________________

This is a sample checklist to assist an Auditor during an onsite audit as a reference in preparing their own custom requirements. It may represent only one approach to satisfying compliance. At a minimum, the firm must replace or insert titles and describe responsibilities that reflect how the work is done at their facility.ConfidentialPage 11/18/15