LPA LAYER 3 QUESTIONAIRRE:

AUDIT AREA:

Page 1 of 3

AUDITOR:

DATE

PART NUMBER(S) AUDITED: ISSUES/COMMENTS/SUGGESTIONS

AUDIT CRITERIA
Safety:

REACTION PLANS
Contact supervisor immediately If not, stop production and remove any safety hazards, clean any spills, and have the operators clean the area to ensure a safe work environment. STOP the job immediately and contact maintenance and engineering immediately. STOP the job immediately and contact maintenance and engineering immediately. STOP the job immediately and contact maintenance and engineering immediately. STOP the operator immediately and contact supervision immediately. If the activity is hazardous, STOP the operator immediately and contact supervision immediately.

S1 S2 S3 S4 S5 S6 S7

Is the Area Safe and the operator wearing Safety glasses? Is the area free of oil/water on the floor, and loose cords or wires, etc. and all machines are clean, areas not cluttered, Do all safety curtains and emergency stops work effectively? Do all safety curtains have the required tool for verification? Is the safety curtain tool attached to the equipment it is to verify? Are the operators wearing all required PPE per the Work Instructions posted for the job? Do you see any unsafe activity that could be changed to increase the safety of this area? Has the 1st Piece been signed off and available in its correct location?

Process :

P1 P2 P3 P4 P5

If not, contact supervisor immediately & Quarantine All Parts. Look @ Inspection Checklist. Review setup sheet for correct materials. If not, contact Do Materials meet Production requirements? supervisor immediately & Quarantine Parts. Are rejected parts identified/tagged correctly and in If not, contact supervisor immediately & Quarantine proper container? Parts. Look around work areas for unidentified parts. Verify that operators are following Work Instructions Are Operators following Standardized work posted at their work station. If not, notify supervisor and Instructions? quality. If not, contact quality to develop. Ask Operator where Are boundary samples readily available? they keep boundary samples. Are trained operators at the work station as per training matrix located in Plex? Look up training Matrix in Plex and Verify all operators are trained to the job they are performing. If not contact supervisor to add the training level to Plex. If not, contact supervisor immediately & Quarantine Parts. Please review Work Instructions & review how glue is being applied to verify. Please verify all repairs are going back through normal process for inspection. Please review the PFMEA and the consequences of shipping a non-conformance to the customer. Contact Maintenance and Supervisor to PM equipment immediately. Contact Quality to determine if the information is communicated appropriately. Contact Quality to determine if the information is communicated appropriately. Contact maintenance to update PM schedule for all equipment nonconforming to this question. Contact engineering to complete a TAKT time study to verify the current production rate. Contact supervisor to update the board and retrain the operator responsible for the information. Issue Date: 06/04/11

P6

P7 Is the line producing to the Appearance Standard? P8 Is glue being applied correctly? Are all repairs processed to go back into the cell for P9 final inspection and verification over error proofing before being shipped to customer? Are the operators aware of the consequences of P10 shipping a non-conformance to the customer? Has the Preventive Maintenance been completed P11 on all equipment in this cell? Is the operator aware of the last nonconformance P12 shipped to the customer? Is the operator aware of the current ppm rate P13 reported by the customer? Has all scheduled PM for all equipment in the cell P14 been completed since the last maintenance interruption in this cell? P15 Is the work cell making the posted production rate?
Process :

P16

Is the posted information on the production board TS-PRC-8222D - Layer 3 questionnaire accurate?

LPA LAYER 3 QUESTIONAIRRE:

AUDIT AREA:

Page 2 of 3

AUDITOR:

DATE

PART NUMBER(S) AUDITED: ISSUES/COMMENTS/SUGGESTIONS

AUDIT CRITERIA
P17 Does the operator have any new ideas or aware of any technologies that would increase efficiency, safety, or customer satisfaction or would reduce scrap, inventory, or rework within the cell?

REACTION PLANS
Contact engineering, maintenance, or quality to determine if these are viable ideas.

Error Proofing

Are there Error Proofing Devices in this process? E1 Check one "Red Rabbit" for effectiveness. Are we verifying these Error Proofing Devices and recording in a log? Is there a certification sticker on the Error proofing E3 device? Has the error proofing device been added to the E4 Master Error Proofing log? E2
Error Proofing

If no Error Proofing devices in cell, mark N/A. If there are Error Proofing devices, verify one works as intended, if it does not work, contact supervisor immediately & Quarantine All Parts If no Error Proofing devices in cell, mark N/A, if No log contact Quality Engineer to develop. If no Error Proofing devices in cell, mark N/A, if No certificate contact Quality Engineer to develop. If no Error Proofing devices in cell, mark N/A, if Not in the log contact Quality Engineer to update. If no Error Proofing devices in cell, mark N/A, if Not leave this blank, if Yes, provide a detailed explanation in the corrective action section. Contact engineering, maintenance, or quality to determine if these are viable ideas.

E5

Are there additional opportunities for Error Proofing?

Does the operator have any new ideas or aware of any technologies for any additional opportunity or E6 changes that would benefit the existing error proofing?
Product

Are the operators using the part gauge for all C1 dimensional requirements?

C2

C3 C4 C5 C6 C7

Verify check sheet is filled out correctly and there is no data out of spec. If not, notify supervisor immediately. If there is data out of specification Quarantine All Parts & contact Quality. Verify check sheet is filled out correctly and there is no data out of spec. If not, notify supervisor immediately. If Are we verifying SPC as required by the customer? there is data out of specification Quarantine All Parts & contact Quality. Verify correct packaging is being used and the labels are Is the correct packaging being used and is the correct. If not, contact supervisor immediately & labeling correct? Quarantine All Parts. Do appearance items meet Customer Specs, eg. Review parts at shipping container & verify they are gouges, short shots, color, etc? good parts and meet customer needs. Does the part fit the gauge for all dimensional Verify part fits the gauge as required. If not, contact requirements as required by the customer? supervisor immediately & Quarantine All Parts. Do the operators feel that there contributions are Contact the Management team and determine how to important to this plant? increase employee motivation. Do the operators feel that there contributions are Contact the Management team and determine how to important to the customer? increase employee empowerment.

TS-PRC-8222D - Layer 3 questionnaire

Issue Date: 06/04/11

LPA LAYER 3 QUESTIONAIRRE:

AUDIT AREA:

Page 3 of 3

AUDITOR:

DATE

PART NUMBER(S) AUDITED: ISSUES/COMMENTS/SUGGESTIONS

AUDIT CRITERIA
Quality System

REACTION PLANS
Stop Job immediately and train all current operators to the Quality Alert. Remove all inactive Quality Alerts and place on Quality Manager's desk. Verify Quality Alerts are still active and not expired, stop Job immediately and train all current operators to the Quality Alert and contact Operations Manager and Supervisor. Quarantine All Parts & contact Quality. Notify supervisor immediately. Remove the container and contact materials immediately and replace with a clean container. Contact Manufacturing Manger to determine competion timing. Contact Quality to develop and or print and place a new job book for this cell. Contact the Manufacturing Manager for resolution. Contact the Director of Quality & Engineering Manager to determine completion timing. Contact the Manufacturing Manager for resolution. Contact the Director of Quality & Engineering Manager to determine completion timing.

Are all ACTIVE quality alerts posted in the cell signed by operators currently in the cell? Are all quality alerts posted in the cell still active (not Q2 expired)? Q1 Q3 Are all active quality alerts posted in the cell being followed?

Q4 Are gauge calibration Tags current? Check one. Are Inspection Check Sheets being filled out Q5 completely and correctly? Q6 Are shipping containers free of debris, rocks, etc.? Q7 Have all Corrective Actions been completed? Q8 Is there a Job book available for the operators. Are the Level 1 LPA audit being completed as required? Are the Level 1 LPA nonconformances being Q10 corrected in a timely manner? Are the Level 2 LPA audit being completed as Q11 required? Have all Level 2 Corrective Actions been Q12 completed? Q9

Comments and suggestions for improving this audit sytem, questionnaire, or format.

I1

Please state improvement suggestions for each area, either updates to the questionnaire for layer 1 and 2, system improvements, or process changes to improve parts or reduce costs.

Non-conformance

LEGEND YES-

NO- X

TS-PRC-8222D - Layer 3 questionnaire

Issue Date: 06/04/11