445788754.

xls Audit Worksheet Printed 11/07/2019

A. Technical Information Availability AUDIT WORKSHEET

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Technical Information DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Availability, REQUIRED

Are the AAM engineering drawings, with the latest Print

Do you have drawings?
1 revision level, available at the supplier's Material Spec Sheets (MS) R ###
Do you have math data?
manufacturing plant? Product Requirement Specs (PR)

Are the Process Flow Diagram, PFMEA, and

Process Flow Diagram, PFMEA, Are these documents at the manufacturing
2 Process Control Plan available at the manufacturing R ###
and Process Control Plan plant?
plant?

Is the AAM part number and correct print

Do the Process Flow Diagram, PFMEA, and
Process Flow Diagram, PFMEA, revision on each document? Do all three
3 Process Control Plan have the correct AAM part R ###
and Process Control Plan documents correlate (have same p/n and
number and print revision level in the header?
print revision number)?

B. Process Flow Diagram (PFD) AUDIT WORKSHEET

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Quality System DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Documentation, REQUIRED

Does the PFD reflect the latest AAM engineering Process Flow Diagram and AAM Is the AAM part number and correct print
4 R ###
drawing/s revison level? Prints revision on the PFDs?

Assure Receiving Inspection matches the

Does the Process Flow Diagram include receiving of
5 Process Flow Diagram Process Flow Diagram and what is observed R ###
material?
on the shop floor.

Assure Rework matches the Process Flow

6 Does the PFD include rework and / or repair? Process Flow Diagram Diagram and what is observed on the shop R ###
floor.

Assure Scrap matches the Process Flow

7 Does the Process Flow Diagram include scrap? Process Flow Diagram Diagram and what is observed on the shop R ###
floor.

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Assure Gauging/Inspection matches the

8 Does the PFD include gauging and inspection? Process Flow Diagram Process Flow Diagram and what is observed R ###
on the shop floor.

Assure Shipping and labeling matches the

9 Does the PFD include labeling and shipping? Process Flow Diagram Process Flow Diagram and what is observed R ###
on the shop floor.

Assure the Process Flow Diagram matches

10 Does the PFD match the actual process flow? Process Flow Diagram R ###
what is observed on the shop floor.

Walk process with focus on "value added"

Does the PFD contain all process steps including and "non-value added" actions performed in
11 Process Flow Diagram R ###
both "value added" and "non-value added" steps? comparison with what is identified in the
Process Flow Diagram.

C. Potential Failure Mode and Effects Analysis (PFMEA) AUDIT WORKSHEET

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Quality System DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Implementation by Management, REQUIRED

Does the PFMEA reflect the latest AAM engineering Is the AAM part number and correct print
12 PFMEA and AAM Prints R ###
drawing/s revison level? revision on the PFMEAs?

Compare all three documents (PFMEA, PCP

Are all steps in the process flow diagram included in
13 PFD and PFMEA and PFD) and make sure all steps are R ###
the PFMEA?
consistent from beginning to end.

Verify that PFMEA is updated as required &

Is there any evidence that the PFMEA has been PFMEA, PFMEA Change Log,
matches Control Plan (Review PRR's).
14 updated as a result of known problems such as PRRs, Meeting Minutes or Similar R ###
Verify any current failure mode is present on
PRRs, etc? History
the PFMEA.

Verify that items with high RPN and/or high

Is there a Continuous Improvement focus for SO numbers and critical line items have
15 reducing high RPN or high Severity Occurrence PFMEA, PFMEA action plans action plans including mistake / error R ###
(SO) numbers? proofing. Are there recurring meetings
dedicated to reducing RPN's?

Verify the PFMEA identifies these

Are all special product/process characteristics
characteristics that are defined on the part
16 identified in the PFMEA (KCCs, KPCs, DRs, PFMEA R ###
print and also customer interface points even
customer interface points, etc.)?
if they are not shown on the part print.

AAM-9F-010Rev. 1
[Link] Audit Worksheet Printed 11/07/2019

D. Process Control Plan (PCP) AUDIT WORKSHEET

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Quality System DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Implementation by Management, REQUIRED

Does the PCP reflect the latest AAM engineering Is the AAM part number and correct print
17 PCP and AAM Prints R ###
drawing/s revison level? revision on the PCPs?

Do the PCP operation numbers match the PFMEA Do operation numbers on all 3 documents
18 PCP, PFD, and PFMEA R ###
and PFD? match?

AAM Prints, PCP, CQI 9

Does the control plan address print requirements
Assessment, AAM Material Review CQI 9 Assessment. Review
19 (i.e. dimensional, material, rust preventative, heat R ###
Specifications (MS), AAM Product Sediment Controls.
treat, surface finish, contamination/sediment, etc.)?
Requirement Specifications (PR)

Are all "current controls" listed on the PFMEA PFMEA and PCP Make sure current controls on the PFMEA
20 R ###
included in the Control Plan? are also shown on the PCP.

Are process controls in place in the PCP to address PFMEA, PFMEA Change Log,
Appropriate Control and/or Redundant
21 the high PFMEA RPN or high Severity Occurrence RPN / SO Reduction Worksheet, R ###
Inspection as appropriate.
(SO) numbers? PCP

Verify the PCP identifies these characteristics

Are all special product/process characteristics
that are defined on the part print and also
22 identified in the PCP (KCCs, KPCs, DRs, customer PCP and AAM Prints R ###
customer interface points even if they are not
interface points, etc.)?
shown on the part print.

Is there a history of failures in spite of

existing controls?
Are sample sizes and check frequencies for each
23 Control Plan Does internal data (scrap, rework, FTQ, etc) R ###
inspection reasonable?
suggest sample sizes and frequency are
adequate?

Are all inspections/tests being performed according Control Charts, Checksheets, Completed documents as required in PCP on
24 R ###
to the PCP? Production Control Boards, etc. floor.

Is inspection data being recorded per the control Control Plan, Inspect Check Sheets, Verify inspections are being recorded per the
25 R ###
plan (SPC data, checksheets, etc.)? SPC charts control plan.

AAM-9F-010Rev. 1
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Ask if rework or repair operations are

performed. If they are, then they need to be
in the control plan.
Does the PCP include rework and repair operations
26 PCP Is rework / repair permissible by AAM R ###
if the supplier performs rework or repair?
Engineering for this commodity of part?
Is AAM aware or has AAM approved this
rework / repair procedure?

For error proofing points where masters are

used to certify a gauge, verify documentation
Dependent on the manufacturing process, does the PCP, Start up checklist and/or
of instructions on how master is used,
27 PCP include error and mistake proofing mastering instructions, presence of masters at R ###
frequency of use and ID # of master. Make
checks? work station.
sure master is tracked and calibrated
annually at a minimum.

For error proofing points where rabbits are

used to certify a gauge, verify documentation
Dependent on the manufacturing process, does the PCP, Start up checklist and/or
of instructions on how the rabbits are used,
28 PCP include verification checks with known good instructions, presence of rabbits at R ###
frequency of use and ID # of rabbits. Make
and bad parts (rabbits)? work station.
sure rabbits are tracked and calibrated
annually at a minimum.

Were causes identified as natural or

Are out of control points noted on the SPC charts SPC Charts, Procedure & Flow assignable? What actions were taken to
29 R ###
with the corrective action taken? Chart correct issue? Was variation measurable
and influenced by actions taken?

Compare the two documents (PCP and PFD)

Is there a "one to one" relationship. Each step in
30 PCP and PFD and make sure all steps are consistent from R ###
the PFD should translate to an action in the PCP.
beginning to end.

E. Gauging, Inspection, and Calibration AUDIT WORKSHEET

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Quality System DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Implementation Plan, REQUIRED

Ensure that Gauge Instructions exist and are

31 Do all gauges have gauge operating instructions? Gauge Instructions posted or available where the gauging takes R ###
place.

Verify gauges have a gauge number on the

32 Are all gauges identified with a gauge number? Gauge Records gauge. R ###

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Ensure AAM brass tag (BT) numbers are on

33 Are all tools identified with a number? Tool Certification Records R ###
tools purchased by AAM or AAM's customer.

Evidence that a system is in place (electronic

and/or manual) tracking all of these items
Is there a system to control, calibrate, and maintain
34 Procedure documentation and verify documentation supports actions R ###
gauges / inspection / test equipment?
are being performed as detailed in the
procedure.

Calibration Stickers on gauges. Check to

make sure gauges are calibrated.
35 Are gauge calibrations up to date? Gauge Records R ###
Verify gauges are to the latest engineering
change level.

Evidence of historical calibration checks

(gages becoming due for certification,
36 Are calibration records retained? Gauge Records R ###
database of gauges, procedure
documentation, etc.).

Check to make sure gauges are certified.

37 Are gauges and masters certified? Gauge Certification Records Verify gauges are to the latest engineering R ###
change level.

Check to make sure tools are certified.

Are tools certified (machine tools, molding /
38 Tool Certification Records Verify tools are to the latest engineering R ###
stamping dies, casting tools, etc.) ?
change level.

Check to make sure that gauge R&R is done

on a yearly basis for all gauges. Gauge R&R
Are Gauge Repeatability and Reproducibility
39 GR&R Documentation should be 10% or less. If gauge R&R is R ###
(GR&R) studies up to date and acceptable?
between 10 and 30 percent then see AIAG
MSA & PPAP Manual for direction.

Is there a procedure instructing what to do with Review procedure that addresses dropped
40 Procedure R ###
dropped or damaged gauges? gauges and what to do with them.

Verify that supplier has actual boundary

Are boundary samples available to operators at the Boundary Samples, Work
41 samples for review or pictures of boundary R ###
work stations where applicable? Instructions
samples.

F. Error Proofing AUDIT WORKSHEET

AAM-9F-010Rev. 1
[Link] Audit Worksheet Printed 11/07/2019

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Quality System DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Implementation by Management, REQUIRED

Verify that customer interface characteristics

Review error and mistake proofing have error and / or mistake proofing to
Is error and / or mistake proofing used for all
42 on the actual equipment, PCP ensure these characteristics are made to R ###
customer interface points.
Samples print specs and any non-conforming parts
are rejected.

Verify documentation of instructions on how

Are known good and bad parts (rabbits) available for Good and Bad part masters, Set-Up
the rabbits are used, frequency of use and ID
43 verification of error and mistake proofing devices at Records, Mastering Verification R ###
# of rabbits. Make sure rabbits are tracked
operator work station? Logs
and calibrated annually at a minimum.

Are rabbit parts error proofed or clearly identified so Visual (paint on part, preferably red,
44 they would not be used by AAM if the rabbits were mutilation to part so AAM is unable Verify presence and condition of rabbits. R ###
accidentally shipped to AAM? to build)

Are rabbits used, on a regular basis, to verify error Good and Bad part masters, Set-Up Verify checksheets are completed as
45 and mistake proofing systems are functioning Records, Mastering Verification described in PCP, PM and / or work R ###
properly? Logs instructions.

Is verification frequency of error and mistake Verify checksheets are completed as

46 proofing devices identified at the work station (i.e. PCP, PM, work instructions described in PCP, PM and / or work R ###
work instructions, check sheets, PCP, etc.)? instructions.

Verify log exists and is completed as

Is error and mistake proofing verification recorded PCP, PM, work instructions,
47 described in PCP, work instructions and / or R ###
and retained in a log? Mastering Verification Logs
Mastering Verification Log.

Are lock boxes used to contain rejects from error / Visual (are lock boxes in place to Walk process with focus on checking
48 R ###
mistake proofing systems? contain rejects or not). presence of lock boxes.

Walk process with focus on checking lock

49 Are lock boxes locked? Visual (lock on lock box). R ###
box status.

Are rejects in lock box reconciled at the end of each

Verify checksheets are completed and
shift and is it documented (i.e. number of rejects on
50 Procedure reaction plan / procedure for rationalizing R ###
machine control panel matches number of rejects in
inventory if discrepancy is found.
lock box)?

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Look for presence of a lock box and make

For manual load/unload systems, are lock boxes sure it has some type of switch (proximity
Lock Box, Switch on lock box
interlocked to machine controls to ensure part is switch, etc) that is activated when part is
51 entrance/chute such as proximity R ###
placed in lock box before fault can be reset and placed in lock box. Test system to make sure
switch, Test the system.
machine restarted. controls will not allow machine to be reset
before part is placed in lock box.

Look for automatic reject systems that

Automatic reject systems, automatic
consider all parts rejects until signal is
reject systems with lock boxes,
received that part is good. For some
Does machine logic prevent non-conforming parts stations that lock part in fixutre if it is
52 operations, part may lock in the station if it is R ###
from being used in downstream operations? non-conforming, manual reject
non-conforming. Look for lock boxes that are
systems with lock boxes interlocked
interlocked to machine controls. Test one or
to machine controls
more systems.

Ask operators if they have the ability to

bypass error proofing systems (if they have
Evidence of password protection,
this ability it is a problem). Have operator
Is there sufficient protection (such as password Error proofing systems that are not
show you if there is password protection for
53 protection) to prevent operators from bypassing the in bypass, Interview operators, test R ###
error proofing bypass (passwords cannot be
error and mistake proofing systems? the system with known good and
accessible to operators). Run known bad
bad parts (rabbits).
part (rabbit) through error proofing system
and see if it rejects.

Ask what happens if an error proofing station

goes down for an extended period of time.
Error proofing deactivation
Is there an error proofing deactivation procedure, for Look for an error proofing deactivation
procedure, error proofing
54 emergency situations, with robust procedure that states countermeasure must R ###
deactivation approval form with area
countermeasures? be implemented if error proofing is bypassed.
to document countermeasures
Examples of signed approval forms that
show the countermeasures that were taken.

G. Work Instructions AUDIT WORKSHEET

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Quality System DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Implementation by Management, REQUIRED

Documented steps for operator to

55 Do operator work instructions exist? perform job (includes set-up Review of work instructions. R ###
instructions and work instructions).

Documented steps for operator to

Are work instructions available for each operation at
56 perform job (includes set-up Review of work instructions. R ###
the work station?
instructions and work instructions).

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Documented steps for operator to

Do work instructions include instructions for set-up
57 perform job (includes set-up Review of work instructions. R ###
and changeover?
instructions and work instructions).

Detailed steps for anyone to

understand how to run the job
Are work instructions detailed enough to run the job
properly (instructions overcome
58 properly, including handling of non-conforming Review of work instructions. R ###
visual, word and color
parts?
error/interpretation) including
handling of non-conforming material.

Is proper disposal of non-conforming setup parts Specific steps for disposal of non-
59 Review of work instructions. R ###
defined in the work instructions? conforming setup parts.

Review of work instructions.

Checksheets, Inspection Question operator if activities aren't
60 Are the work instructions being followed? R ###
Checksheets, Control Charts, etc. performed according to the written work
instructions.

Look for training matrix and / or lists that

Have operators been trained and is there Formal training matrix, certification,
61 have been updated within a reasonable time R ###
documented evidence? lists, etc.
frame.

Is part quality verification following a tool change

62 Work Instruction, Checksheets Look for Intrusctions and Check Sheet. R ###
documented in the work instructions?

Details of customer interface points

Are customer interface points identified at the work
63 (CIP) through use of KPC's, Pictures Review of work instructions. R ###
station?
with highlights, CC's, etc.

H. Material Handling AUDIT WORKSHEET

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Quality System DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Implementation by Management, REQUIRED

Specific part condition, stacking, damaged

For work in process (WIP), does the material
No excessive rust, dirt or debris, containers.
64 handling system and packaging prevent parts from R ###
evidence of handling damage. Is handling minimized (where practical) to
being damaged?
reduce risk of damage?

AAM-9F-010Rev. 1
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Are instructions for handling WIP and final product Work instructions per operation,
65 followed throughout the process to the shipping includes any identified in-process or Review of work instructions. R ###
area; including repair/rework areas? shippable dunnage

Part / container labels or tags are for

Look for completed information on all
66 Are all parts and components labeled properly? the proper material in the proper R ###
identification labels / tags.
state.

Does method for material identification,

Does error proofing exist to prevent part PCP, pack-out / shipping verification
67 traceability and test status exist throughout R ###
misidentification (wrong label)? procedure
all production stages for this part?

Is adequate protection used to protect ferrous metal Specific part condition at individual
68 Visual (no rust). R ###
parts from rust? operations.

I. Control of Non-conforming Material AUDIT WORKSHEET

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Quality System DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Implementation by Management, REQUIRED

Does supplier have a non-conforming material Non-conforming material handling Let me see your non-conforming material
69 R ###
handling procedure? procedure. handling procedure.

Look for non-conforming material handling

procedure that is posted or in a binder that is
Is the non-conforming material handling procedure Non-conforming material handling
70 accessible to the operators. Also could be Y ###
readily available to the operators? procedure.
accessible to operators through a computer
terminal.

Separate containers tagged for Look for good part containers tagged
Are separate containers identified and available for good parts, separate containers properly at the work cell. Scrap and rework
71 R ###
good, rework, and scrap parts? tagged or labeled rework, separate containers need to be clearly tagged and / or
containers tagged or labeled scrap. labeled.

Look for scrap containers at the work cell or

Do operators have easy access to scrap containers
72 Containers tagged or labeled scrap. in an area that is easily accessible by the R ###
for immediately disposing of scrap parts?
operators.

Scrap containers identified by a Look for scrap and rework containers that
Are scrap and rework containers properly color
73 unique color. Rework containers are color coded such as red for scrap and R ###
coded (i.e. scrap = red, rework = yellow, etc.)?
identified by a unique color. yellow for rework.

AAM-9F-010Rev. 1
[Link] Audit Worksheet Printed 11/07/2019

Look for a suspect material and non-

Non-conforming material tags. Hold
conforming material tagging procedure that
Is a consistent tagging system used to clearly for disposition tags. Tagging
74 clearly identifies what type of tag to use. R ###
identify suspect and non-conforming material? procedure. Non-conforming material
Non-conforming mateiral procedure should
handling procedure.
address how to tag non-conforming material.

Are tags readily available to the operators for Good (conforming) material tags. Look for new (unused) tags staged at the
75 identifying non-conforming material (i.e. scrap tags, Non-conforming material tags. Hold work cell or located in an area that is easily R ###
hold for disposition, ect.)? for disposition tags. accessible by the operators.

Suspect and non-conforming Look for suspect and non-conforming

Is suspect and non-conforming material segregated material quarantine areas. Non- material and make sure it is in clearly marked
76 R ###
in properly identified areas? conforming material handling areas that are only used for suspect and
procedure. non-conforming material.

Do you have a material review board? Look

for designated scrap segregation areas. Look
Material Review Board, Non-
Is scrap reviewed and disposed of in a way that for designated scrap segregation areas that
conforming material handling
77 prevents mixing with good material or prevents are clearly identified (foot printed, signs, etc). R ###
procedure, scrap review areas,
reintroduction into the normal material flow? Confirmed scrap to be clearly identified with
scrap tags on bins
tags/paint/destruction, etc) so it would not be
reintroduced to normal material flow.

J. General AUDIT WORKSHEET

QUESTION: EVIDENCE /
QUESTIONS TO ASK AND WHAT
In regard to Quality System DOCUMENTATION Score G/Y/R OBSERVATIONS
TO LOOK FOR
Implementation by Management, REQUIRED

Look for open PM work orders and verify

they are not past due. Verify PM work orders
Is there a Preventive Maintenance (PM) plan on
Open PM work orders, Completed are completed/closed and retained. Are PM's
78 tools (fixtures, dies, etc.) and is there evidence that R ###
PM work orders. being performed on time?Tool life tracking
it is being followed?
program to be in place if tooling PM is
triggered by number of pieces on tool.

Look for open PM work orders and verify

Is there a PM plan on equipment and is there Open PM work orders, Completed they are not past due. Verify PM work orders
79 R ###
evidence that it is being followed? PM work orders. are completed/closed and [Link] PM's
being performed on time?

AAM-9F-010Rev. 1
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Look for a computer based PM system that

Is there a system to control the PM plans and issue
automatically generates PM work orders at
PM work orders such as an electronic system that Electronic (computer based) PM
80 specified intervals. Ask supplier to R ###
automatically generates work orders at the specified system
demonstrate how a work order is generated
PM intervals?
and closed out.

Look for spare parts and tools that are stored

Spare parts crib/store, tooling
in designated areas such as spare
crib/store/vending machine. Spare
parts/tooling cribs or stores. Look for system
Does the supplier have a spare parts and spare part and tooling inventory tracking
that automatically reorders (or prompts
81 tooling program and can they provide evidence that and reordering system. Current R ###
reorder of) spare parts and tooling once a
adequate spare parts and tools are available? inventory status of spare parts and
minimum inventory level is reached. Are
tools. Spare part/tooling lists for
min/max inventory levels established for
specific pieces of equipment.
spare parts and tooling?

Look for completed audits on final product.

Final part inspection audits, dock This could be in a designated area or where
82 Are audits being performed on final product? R ###
audits, layered audits. the parts are packed for shipment. Look for
completed dock audits and layered audits.

Check that supplier has approved PPAP's for

Do sub-suppliers provide evidence that PPAP Sub-Supplier PPAP packages, incoming material. Review incoming
83 approved material and certified material is used in Certifications (material, dimensional, certifications with material/parts/assemblies R ###
all components that they supply? heat treat, etc.), Test Records such as; material, heat treat, dimensional
certifications,etc.

Sub-Supplier PPAP packages, How do you indicate that incoming

Are controls in place to ensure only approved
84 Certifications (material, dimensional, parts/assemblies to the manufacturing floor R ###
incoming material is used for production?
heat treat, etc.), Test Records. are approved prior to release for production.

Look for lot controls, dimensional traceability,

Traceabiliy documents/procedure,
When parts require traceability, does the system link heat lot traceability, etc. Ask supplier to show
85 Sub-component and final part R ###
sub-component traceability to the final part? you how the sub-components are linked to
traceability logs or database.
the final part for traceability.

Look for existing charts for each metric and

are these charts visible at the plant? How
Is there a process for documenting and tracking
Plant information board, Current often are they updated and who does it? Also
86 scrap, customer issues, downtime, and first time R ###
charting of information look for data logs, actions plans, etc. that
quality?
validate the existence of a process for
documenting and tracking these metrics.

AAM-9F-010Rev. 1
[Link] Audit Worksheet Printed 11/07/2019

Look for existing charts, quality alerts, data

Plant information board, Current
logs, actions plans, corrective action reports,
Is there a process for documenting and tracking charting of information, Quality
87 etc. that validate the existence of a process R ###
internal plant quality issues? Alerts, Internal Corrective Action
for documenting and tracking internal quality
Reports
issues.

Ask to see an example of a current action

Are action plans used to help ensure tasks are
plan. Check to see that it follows the basic
completed and implemented on time (key items in
88 Action plans format (task/action item, person responsible, R ###
action plan: task/action item, person responsible,
planned & actual start and finish dates) and
planned & actual start and finish dates)?
that it is being updated regularly.

Ask the supplier to explain their escalation

Does an escalation process exist to quickly Record of daily leadership meetings process and show evidence that it is being
communicate quality issues to the appropriate where quality concerns are [Link] to see documentation such as
89 R ###
people within the organization and ensure that communicated and addressed. Log their daily leadership meeting records, quality
issues are addressed. of issues. issues log, action plans. Verify that the
records are being updated regularly.

Record of daily quality meetings for Look for evidence that operators are
Are operators involved in the problem resolution each shift on the shop floor involving informed of quality issues and involved in the
90 process and are they aware of how problems are operators, board documenting problem resolution process. Ask operators if R ###
resolved? issues, action plans, and corrective they are aware of quality problems and if
actions. they are involved in resolving them.

Look for shift logs/notes. Look for evidence

of a closed loop on shift problems. Audit
If more than one shift is utilized, is there a system to
91 Shift log, shift communication board records to assure that reported problems and R ###
pass information across shifts?
their resolutions are also reported back to the
originator.

###

Approved ✘ Approved, but need Documentation Rejected

Follow-Up Audit Date: ____________________

Supplier Representative Signature AAM Representative Signature

AAM-9F-010Rev. 1
 AAM Supplier Quality Audit Summary Sheet
Date: 5-Sep-14

Supplier Name: Supplier Phone:

Mfg. DUNS: Plant Location & Country:

Auditor: Auditor Phone:

Auditor: E-Mail: AAM Division:

Part Number (s): Part Name:

PPAP/Interim/Status: Program:

Reason For Audit:

Future Launch✘ Current Partial Other Safety Related Part ? ✘ Yes No N/A
Type of Audit: Initial✘ Follow UpRun at Rate (SP9) Product Validation/Qualification Complete: ✘ Yes No N/A

Driver of Audit: APQP Confirmation Corrective Action Verification Warranty Issue

Quality Issue/s Shutdown/Start Up Audit ✘ Other
SPR Follow-up
Focus of Audit: Part / Assembly
✘ Line /Cell Operation / MachineComplete Mfg. System Quality System - Ongoing Documentation

Approved ✘ Not Approved Follow-Up Audit Date:

Chart Title
1
Score

0.8
0.6
0.4
0.2
0
Technical Information
Process
Potential
Availability
Flow
Failure
Diragram
Mode (PFD)
and
Process
Effects
Gauging,
Control
Analysis
Plan
Inspection,
(PFMEA)
(PCP) and
Error
Calibration
Proofing
Work Instructions
Material
Control
Handling
of Non-ConformingGeneral
Material

Each Score is color-coded according to the highest severity finding in that section

Yellow Green Total

Score RED Items Items Items Items
Technical Information Availability 3 0 0 0
Process Flow Diragram (PFD) 8 0 0 0
Potential Failure Mode and Effects Analysis (PFMEA) 5 0 0 0
Process Control Plan (PCP) 14 0 0 0
Gauging, Inspection, and Calibration 11 0 0 0
Error Proofing 13 0 0 0
Work Instructions 9 0 0 0
Material Handling 5 0 0 0
Control of Non-Conforming Material 8 1 0 0
General 14 0 0 0

Overall Score #DIV/0! 90 1 0 91

Auditors Comments:

Supplier Representative Signature AAM Representative Signature

AAM-9F-010Rev. 1
 0 Element is not in place and no evidence of plans to implement

1 Element is not in place but a plan to implement is documented

2 Element is in place but it is not being followed

3 Element in place but not followed at each job or all the time

4 Element is in place and it is being followed

NA Not Applicable

NR Not Reviewed
Audit Worksheet
1 Select the score (Column E) for each element based on the audit result.
Select NA for "Not Applicable"
Select "NR" for "Not Reviewed"
Note: NA and NR values are not included in audit results or calculations.
2 Score totals and color coding are created automatically, and are not user variables.
3 Enter observations (Column G) in the box adjacent to the appropriate element.
4 Elements may be added, deleted or edited as necessary, but new elements must be added BEFORE the last eleme

Audit Summary
1 Enter the appropriate header information (Row 1 - 37)
2 Audit score charts and tables are created automatically and are not user variables.
3 Enter the Auditor comments and signatures as required (Row 75 - 87)

Lists
1 Lists may not be edited and are not user variables.
d BEFORE the last element in each section.