audit check list_investment casting foundry

8/12/2019 Audit Check List_investment Casting Foundry

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FLOWLINK SYSTEMS. ARASUR urvey Items: Castings

Company Name Questionnaires Reply (to be filled by Vendor)

CompanyOverallInformation

1.

CompanyOutline

Registered

company name

Registered

company address

Head office

address

Factory names

and addresses

List all the factories:

Company

representative

(i.e. CEO or

resident!

"ame

Contact person "ame

#elephone num$er

Facsimile num$er E%mail address

Esta$lished year

&ain products

Customers &a'or Overseas

Customers (past 1 years! )or*ing hours )or*ing Hours +& : to & :

(Lunch ,rea* : to : !

"um$er of -or* shifts :

Holiday

Others Competitive roducts

#echnical advantages of

your company

Commercial advantages ofyour company

our Competitors


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Company Name Questionnaires Reply (to be filled by Vendor)

CompanyOverallInformation

1.CompanyOutline

#otal num$er of

employees

"um$er of

employees of

each department

&anagements

+dministrators

rocurement staffs

E/peditors

0uality assurance staffs

0uality control staffs

R# ualified e/aminers ( ! for in%house2 3 4 for outsourcing

5# ualified e/aminers ( ! for in%house2 3 4 for outsourcing

# ualified e/aminers ( ! for in%house2 3 4 for outsourcing

ualified e/aminers ( ! for in%house2 3 4 for outsourcing

&etallurgists

Casting lan(&ethodology! Engineer

roduction engineers

Certified -elders

)elding supervisors

Factory -or*ers

Other staffs

6.0uality+ssurance 78O 91 Certification es"o

Has company internal

ualification system for

inspectors

es"o

+8&E2 +72 etc Certification List the certifications:


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Factory Name and LocationQuestionnaires Reply (to be filled by Vendor)

% "o2 -e cannot do machining -or*.

&anufacturing

Euipment

details

(in addition2

please su$mit

the list of all

euipment in

the factory!

Cranes 7ndoor:

Outdoor:

&elting furnaces Capacity:

Refining furnace es"o2

7f yes:

->escri$e details2 and

- )hich case do you use it

)elding &achines

Heat treatment furnaces Capacity and &a/imum temperature

0uenching pool

&achining

#esting and

7nspection

Euipment

details

(in addition2

please su$mit

the list of all

euipment in

the factory!

&7 euipment

F" chec*er

# solvents

euipment

5# euipment

R# euipment

Reference radiograph +8#&s +8#& E1D (originals2 not copies!: es or "o

+8#& E (originals2 not copies!: es or "o

R# room

ressure testing Hydrostatic:

neumatic:

.roc

urements 8craps )hat are your uality

reuirements of scraps

Ho- do you verify uality of

scraps

7s &7 applied to scraps


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InformationofEac

Foundry -hen received

7f yes:

a!Ho- freuent

$!Ho- do you record the &7

results

>oes the foundry control

$ac* remeltreturn scrap $y

alloy

8u$%contracts:

such as casting

plan

(methodology!2

mould ma*ing2

">E2

mechanical

testing2 heat

treatment etc.

Range of su$%contracts

(scope of services!

8u$%contractors

A.Castinglan(&ethodology

!

Casting lan

(&ethodology!

)ho prepares2 revie-s2 and

approves casting plans

Ho- long e/perience do they

have

Have you ever $een instructed

$y any other company ho-

casting plans are esta$lished

7f yes2 please indicate the

details.

Ho- do you esta$lish and

ualify prototype casting

plans (for ne- materials2

shapes2 or thic*ness castings!

a! #rial products and their

evaluation details (-ho2

ho-!.

$! Feed$ac* from the

evaluation results.

c! +cceptance Criteria.


6/15


>ie for &a*ing

patterns

a! )ho manufactures dies

(7n%house 8u$contract!

$! )ho designs a >ie

&ould >o you have any procedures

for &ould ma*ing

7f yes2 please e/plain it$riefly.

lease descri$e typical sand

conditions.

a! 8and #ype

$! Composition

c! Grain fineness

d! +dditives

>o you have any procedures

for drying the moulds

7f yes2 please e/plain it

$riefly.

>ies Ho- do you control die

conditions2 such as

dimensions2 surface

roughness

)hat criteria do you have

attern )hat type of -a/ use

)hat is a 0C chec* used for

attern -a/

ouring >o you have dedicated

melting furnaces for each

material

7f one melting furnace is used

for various materials2 is thereany special care


7/15


Ho- is the pouring

temperature controlled

7s the pouring procedure

esta$lished


$riefly.

a! Ho- to pour melting

metal into mould

$! Ho- to remove slag

c! ouring temperature

d! ouring speed (rate! (!

e! ouring time (!

(! should $e varied

depending on casting

siIe-eight

Ho- chemical composition is

controlled against the code

reuirements

Ho- is off%spec castingshandled

@noc*%out >o you have *noc*%out

procedure


$riefly.

a! &ould removal

$! 8ha*e out (sand

removal!

c! Riser removal

d! ,lasting

e! ?isual chec*

ield Ratio lease indicate typical yield

ratio in your foundry.

a! Car$on steel and L#C8

$! Lo- +lloy 8teel

c! +ustenitic stainless

steel


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)elding )hat are your company

standard criteria to 'udge

casting -ith defects -hether

to $e repair -elded or to $e

re'ected (scraped!

Ho- do you monitor -elding

conditions

List of -elding procedures to

+8&E 8ec 7J.

reheat for -elding

Rod ovens used

(&ain oven Flas* oven!

Ho- are the )80Rs

handled to $e complied

during manufacturing

For e/ample2 provided for

each -elder or2 displayed in

shop

Ho- are the -elding

electrodes controlled -ith

regard to drying temperature

and hours

7n -hat case do you perform

)H# for -elding repair as

your company standard

Heat #reatment Ho- many furnaces

8iIe

#ype of Furnace

(Oil fired Electric!

+re there any procedures

ho- to stac* the castings in

furnace


$riefly.


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Ho- do you verify the metal

temperature in the stac*ed

condition in furnace

Ho- do you monitor the heat

treatment conditions

a! lease indicate loading

method of castings from

heat treatment furnace to

uenching pool2 such as

automatic or $y manual.

$! lease indicate the

ma/imum allo-a$le time

to move casting from heat

treatment furnace to

uenching pool2 for:

$%1 ! +ustenitic stainless

steel

$%6 ! 66Cr duple/

stainless steel

$%; ! 6ACr super duple/stainless steel

0uench #an* 8iIe

+gitation

lease indicate the -ater

uenching facilities.

a! )ater chilling method

$! >istance $et-een -ater

pool and heat treatment

furnace

c! Ho- to control -ater

temperature

d! Capacity

e! Ho- to stir the -ater

Cali$ration of

Heat #reatment

Furnace

&ulti point 8urvey

Ho- often

Cali$ration according to


10/15


Cali$ration of recorders K

controllers

Ho- often

O$tained Cali$ration

Certificates

0uench evaluation $y

&etallographic test done

Ho- often

#est $ar -ith castings

through all cycles

Ho- are heat treated

castings identified

7dentification and

8torage

Ho- do you identify and store

castings to $e repair -elded

Ho- do you identify and store

re'ected (to $e scraped!

castings

L.0uality

Control Casting 0uality

Control

Ho- do you control casting

uality

>o you perform any ">E or

metallurgical mechanical

tests in daily production as

your company standard (if

purchaser specify nothing!

Ho-2 -hen2 and ho- many

times are the mechanical

properties measured

)hat is the relationship to

heat treatment $atch

Ho-2 -hen2 and ho- many

times are the chemical

compositions analyIed


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)hat are the casting defect

acceptance criteria in your

company standard For

e/ample2 defect siIe2 defect

depth2 defect type2 repair

volume2 materials.

lease inform us of the

follo-ing cases:

a! +ccepta$le castings

-ithout repair -elding

- 8urface defects

-7nternal defects

$! +ccepta$le castings -ith

repair -elding

- 8urface defects

- 7nternal defects

c! Re'ected (to $e scraped!

castings

- 8urface defects

-

7nternal defects>o you maintain a record of

casting defects 7f yes2 ho-

much is your defect ratio in

past ; years

a! +ccepta$le castings -ith

grinding $ut -ithout

repair -elding

$! +ccepta$le castings -ith

repair -elding

c! Re'ected (to $e scraped!

castings

Re'ection ratios:

a! casting re'ected $y

internal inspection

$! casting re'ected $y ;rd

party (or customer!

inspection


12/15


)ho has responsi$ility for

'udging -hether a casting to

$e accepted2 accepted -ith

repair -eld2 or re'ected

(scrapped!

"on

Conformances

>o you maintain a record of

"CR ("on%conformance

report!

7f yes2 -hat is your non%

conformance ratio in past ;

years


13/15


Cali$ration of

test euipments

(i! List type2 $rand2

and model of euipment

used to perform chemical

analysis.

(ii! 7s the euipment

used for the chemical

analysis cali$rated in

accordance -ith the

applica$le specification or

manufacturerMs

recommendations

(iii! +re the standards

used to cali$rate the test

euipment tracea$le to a

"78# standard or other

recogniIed organiIation

(iv! +re the standards

used representative of the

full range of alloys

produced $y the facility(v! 7s the testing

euipment capa$le of

reporting full uantitative

values2 including trace

elements2 for the alloys

produced $y the foundry

(vi! 7s a documented

procedure used for

preparing the test

coupons and

accomplishing the

mechanical property

testing

(vii! 7s this procedure

availa$le at the -or*ing

level

(viii! 7s there a

documented training plan2

including training records2

for this procedure


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8tandards used &88%8%AA2

+8#& E2

+7 +

+8#& +;A6

+8#& +;A1

+8#& +;

+8#& +;

Other N as applica$le


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!ocuments to be submitted by vendor"

!ocument #itle to be filled out by Vendor

!ocument umber Revision or

Issue !ate

1 Company ,rochure

6 roduct ,rochure

; Company 0uality &anual

Company OrganiIation Chart

A Copy of ualifications certificates

Companys standard technical and 0C

documents:

1! #ypical casting plan (methodology!

6! 7nspection and #esting lan

;! )80R

(C82 Lo- alloy steels2 +ustenitic

stainless steels!

! Heat #reatment rocedures

(C82 Lo- alloy steels2 +ustenitic

stainless steels!

A! Heat #reatment Furnace ?erification

Records

! &aterial #racea$ility rocedure

! ">E procedures (#R#5#!

D! ,lasting rocedurepic*ling passivation

9! ac*ing procedure

Foundry Layout 8*etch or >ra-ing

D List of &anufacturing2 #esting2 and 7nspection

Euipment

9 Ra- material supplier list

1 8u$%contractor list

audit check list_investment casting foundry

Documents