Process Name - Injection Molding

Version: 1.7 Issue Date: Oct. 31st, 2013

Auditor: Date: Score
Supplier: Location: 0%
Duns: Part Name: RED

A. Technical Information availability on this specific part AUDIT WORKSHEET

EVIDENCE/ G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

(1) Blue Print

Are actual GM approved drawings available at the
Enter required evidence (2) Math Data
1 Production facility, with the latest Engineering Change Level 1 R ###
description (3) Material Specification sheets
for this part, and all applicable components?
(4) Check for latest EWO and revision date.

(1) Completed and Approved Engineering Drawings.

Is the print complete (Tolerances, GD&T, Correct Datum's,
2 (2) Verify that print has all information (if applicable, time wise). NR NR ###
KPCs, etc.)?
(3) Full Approved PPAP package of part and applicable component/s.

(1) Part Print/Specifications package.

3 Are all Technical Regulations / CTS / SSTS available? (2) Verify component technical specifications are available for NR NR ###
review.

Has Molder supplier endorsed the process parameters base (1)MSDS and Material Manufacturers guidelines provided by resin
4 on MSDS and Molding Guide provided by resin supplier. supplier. NR NR ###
(2)Sign off documents i.e. process control check sheet

Check for latest moldflow analysis.

5 Does the parts reflect on the latest moldflow analysis?
(gate locations,molding feasibility,surface defects, deflection etc.)
NR NR ###

Total

B. Quality System Documentation and Implementation AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

(1) Latest updated Process Flow/PFMEA/Control Plan/Work

Instructions.
(2) Verify that all these documents are updated to the latest
Does the part have Flow Diagram, PFMEA, Control Plan, Enter required evidence
1 Engineering Change Level. NR NR ###
Work Instructions? description (3) Evidence of being living documents. Validate through the revision
log.
(4) Conduct an historical change matrix review.

Does the Press Station have a Takt Board/Log with defects (1) Updated Takt Board/Logs.
per hour and proper alarming limit? (such as FTQ<95%, (2) Verify that this is being used.
2 (3) Operator is marking progressively and not at the end of the
NR NR ###
alerting to TL; <90%, stop prodution and alert to TL and PE,
etc) shift/operation.

3 Does the layout of the Press Station follow 5S procedures? Verify 5S process utilized to develop work cell layout. NR NR ###

(1) Operation to verify the machine setup vs. work instruction.

(2) Critical dimensions should be identified by the supplier to meet
the design intent, and agreed /approved by the customer.
(3) Before start of actual production, all the critical dimensions need
to meet the specifications to print, and signed off by the Operations
Team of the supplier and bought off by the Quality team. The in
Is the procedure for parts produced before the first off process inspection sheet be signed as the objective evidence. Parts
approval available?
molded before first off approval should not be used for production.
4 Is there a 1st Piece / last Piece inspection?
(4) The maintenance team understands the difference between the
NR NR ###
first and the last piece.
(5) Comes to an agreement on the maintenance required on the tool
in addition to the preventive maintenance dictated by the
tooling/machine. This would be based on the evaluation of the 1st
and last off inspection.
(6) Keeps a track of the improvement post maintenance by
comparing to the defects produced prior to the maintenance.

(1) Training records.

(2) Verify consistency on good parts packed for down stream
5 Is the operator trained to run the part? operations. NR NR ###
(3) Number of rejected parts.
(4) Number of reworked parts.

(1) Check the Control Plan for frequency of gauging.

6 Are parts being gauged prior to packaging? NR NR ###
(2) Check the documentation at the press station.

(1) Check the GM approved drawing.

(2) Check the work instructions.
7 Does the part have a KPC? NR NR ###
(3) Is the station highlighted with the KPC symbol on the station and
the work instruction.

(1) Check for PRR and its response.

Are standardized problem solving form (e.g. PPSR/DDW)
8 (2) Speak to the operator and confirm his/her involvement and NR NR ###
used at the station for initiation of root causing an issue?
understanding on the problem solving.

Part Weight should be referenced on Control Plan, inspection sheet,

etc. & checked at first piece, in process inspection intervals, and last
9 Does the supplier weigh its parts? piece. Tolerance would depend on overall weight and size of the NR NR ###
part. Part weight with runner is a very important control and
reference for Injection Molding Process.

(1) Part specific quality check list.(such as Key DIM, shot weight,
appearance, function if needed,etc)
Is there a quality check list for the part? In process (2) Frequency of checks conducted. (recommending per 3hr or 2hr)
10 inspection sheet? NR NR ###
(3) Does this frequency match with the Control Plan?
(4) Is there a written contingency plan standardized work instruction?
Include contact list in case of discrepant part escape.

What is the procedure for the parts molded before last off
11 Parts should be quarantined and have 100% check before releasing. NR NR ###
approval if it is not to specification?

Does the COO marking appear somewhere on the part? If not, does
COO marking label appear on the individual box/bag the single part
CCA (service parts) Country of Origin (COO) Marking, if is packaged in? If not, does COO marking label appear on bulk
12 plastic bag inside shipping container? Fasteners, bulk sheet metal,
NR NR ###
available, engraved on back of parts/tooling
and parts where COO would adversely affect class A surface are
exempt from COO requirement.

(1) Does the storage tank and drier meet the requirements of
Is the storage tank and drier controlled by low/high level drying.
13 NR NR ###
to minimize downtime and ensure quality stability? (?? ℃× ?? Hrs)
--> Install level sensor and alarm for low/high level.
Total

C. Contamination Plan AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
 Evidence of a plan to prevent cross contamination. Who is
Receiving/Storage Silo/Gaylord/Barrel/Bag Contamination Enter required evidence
1 authorized? What is checked/verified? How checked /verified? NR NR ###
Control Plan description Evidence of check/verification.

Evidence of a plan to prevent cross contamination. Who is

authorized? What is checked/verified? How checked /verified?
2 Manufacturing/Processing Contamination Control Plan NR NR ###
Evidence of check/verification. Evidence of inclusion in Layered
Process Audits.

Evidence of a contamination reaction plan. Plan for

3 Contamination Reaction Plan NR NR ###
damaged/leaking resin containers.
Pipes/hoses positively and frequently marked/identified, color
4 Process/Maintenance Contamination Control coded, and locked. Hard error proofing different sized hoses/hose NR NR ###
connectors. Lids on all resin containers.

For traceability, all parts should have month, day, year marking at
5 Traceability minimum. Recommended: month, day, year, shift, 24 hour, cavity. NR NR ###

Does the supplier use the storage tank and drier of raw (1) Common use for raw material can cause quality
6 NR NR ###
material for common use? issues(appearance, dimension and physical properties).
Total

D. Process Parameters AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

(1) Check the record of Mold Flow analysis during tooling design and
verification, refer to GMW16355
(2) Supplier should set up a completed and proper parameter Spec
sheet with proper upper&lower control limits supported by Material
Is there validated and proper, completed Process manufacturers guidelines, Mold Flow Analysis and tooling try out
Parameters Instruction Sheet posted on the station? Enter required evidence before PPAP.
1 Is it endorsed by cross function team and released officially? (3) Molding Machine No.,material type, colorant ratio(if necessary), NR NR ###
description
Is it the latest version? drying Temp.&Time should be clarified on Instruction Sheet.
(4) Injection Speed/Pressure/Temp., Hold Time, Hold pressure,
Cooling Time, Cushion Location,Clamping time, Mold Cavity/Core
Temp., Hot Runer Temp.(if necessary), etc should be included in
Sheet at least.

Is supplier using correct/defined Injection Molding Check actual machine on floor vs Parameters Instruction Sheet
2 Machine? noted.
NR NR ###

(1) GM material validation certification.

(2) GM lab approval.
(3) Material notes on the print.
(4) Material specification sheet.
(5) Verify material.
(6) Is the material being de-moisturized properly? Especially bibulous
and Easy hydrolysis resin, such as
PA、PET、PBT、POM、PC、ABS、PMMA etc.
Is the correct material used for the part in production? (7) Resin should be de-moistureized with strictly and properly Temp.
3 and Time before upload to Molding Machine
NR NR ###
(8) Is the regrind usage per GM specified standards.Verify regrind %
usage and log.
(9)Mixing ratio shall to be controlled uniformly . Pallet size for
regrind material need to be controlled.
-->Different size of pallet can cause poor mixing ratio. Periodic
verification shall be performed at the machine hopper.
-->Does the supplier have the evidence of approval for using
regrind material.(GM3660,AAR,PPAP)

(1) Control plan/Instruction Sheet should have required colorant

listed along with base resin. Verify correct colorant and mixture ratio
is being used if material is mixed.
Is the correct colorant being used if required for the part in (2) Normally plastic grain with color masterbatch made up by raw
4 production? NR NR ###
material supplier.
If mixed on-site for some special reason, ratio should be consistent
and make sure mixing well, color& gloss must be checked before
molding process.

(1) Is there a standardized work instruction for loading and

distribution of the material from the silos.
(2) Are the silos and the connecting hoses color coded for visual
management to distinguish between different resins/material being
5 Is the material stored in silos? used. NR NR ###
(3) Is the material being tested in the in-house lab for Sp. Gravity,
Flow properties etc. prior to being unloaded in the silos.
(4) Is every bulk load accompanied by the manufacturers certificate
of analysis.

(1) Is there a standardized work instruction for switching the uptake

of material from silos to gaylord.
(2) Are the connecting distribution hoses color coded for different
In an emergency (like material shortage/current weak
materials?
market conditions, low volume order justifying smaller
6 (3) Are the gaylords labeled with similar color coded labels to NR NR ###
packaging etc.) does the supplier use gaylords to receive
distinguish different materials?
small quantities of the material
(4) How is the material usage from gaylord/s verified at the press?
(5) Who are involved in verification that the correct material is used
for the part being produced

Verify if Operation is following the Spec sheet completely on floor,

Is supplier using correct/defined Injection Molding Process
7 Control panel of parameters should be locked and authorized by NR NR ###
Parameters?
Engineer.

(1) Mold Temp. Controler is necessary for appearance parts and

crystalline material to avoid appearance defects and stress/warpage
Is supplier using Mold Temp. Controlers to control Mold
8 due to shrinkage, Crystalline Material: PA66, PA6, POM, PP etc. NR NR ###
Cavity/Core temperature? Is it following Spec Sheet?
(2) Best Practice: 2 Mold Temp. Controler are prefered, one for
Cavity and the other for Core.

(1) Does the part require conditioning to meet stress/strain

requirements?
9 Part Conditioning (2) Has the time been validated and approved by GM? NR NR ###
(3) Check test data and controls in place to verify parts are
consistently meeting specification.

(1) Used to track changes made to the molding process if increased

number of defects are starting to be produced.
(2) Review the deviation log for major changes to the process.
(3) If changes are made and parameters are modified outside of the
Is a process deviation log present to monitor any
process windows, parts must have all quality checks performed to
10 adjustments made to the process outside of the tolerances NR NR ###
ensure it is acceptable and approved by quality manager. If
listed on the process parameter check sheet?
applicable, customer must be notified to review, as well.
(4) If deviation is going to be a permanent change, how is process
parameter check sheet updated with new parameters and how is
updated process approved.

Total

E. Post Molding Process AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R
 (1) List of defects that part can produce.
Is the operator trained to check for defects? Enter required evidence (2) Verify that the Takt Board at the press or production log sheet at
1 NR NR ###
description the station is pre populated with all known potential defects.

(1) Control plan should specify frequency and the number of parts to
be verified.
2 Does the operator gage parts? NR NR ###
(2) Is the gage calibrated?
(3) Check completed documentation at the station.

(1) Typically N Pcs./Hr. or Shift.

(2) calculate quantities and determine based on ship quantities,
3 Is the sample size adequate? whether the supplier has the capability of sorting in-house, if the NR NR ###
parts have failed gauging, inventory to make expedited shipments,
etc.

Does the part require deflashing, trimming and other (1) Verify shoot/inspect/ship or inventoried for downstream
4 operations prior to be moved to the downstream operations operations. NR NR ###
(paint/assemble) or pack shipment. (2) Check process flow and work instructions.

(1) Check for physical presence of the boundary sample at the

station.
5 Is GM approved boundary sample available at the station? NR NR ###
(2) Is the boundary sample well maintained. Is it signed by a quality
representative?

(1) Labeling instructions.

Is labeling engraved in the tooling or requires additional
6 (2) Labeling PFMEA available? NR NR ###
manual labeling for traceability?

(1) Depending on the part, there could be different combinations.

(2) GM ship containers are not used as WIP containers.
Is the GM container used for WIP? Or it is the one specially (3) Are there sufficient GM containers in the supplier system.
7 developed and paid for by GM for the program, or it is (4) Does the supplier understand that shipping in expendables have NR NR ###
returnable/expandable. to be authorized, if returnable not available.
(5) Shipping and logistics records to be verified. Verify packaging
instructions.

(1) Verify the containers/dunnage being used.

Does the part require a special dunnage for protection (2) Check internal dunnage.
8 within the container? (3) Check for special part protection like Tyvek covers and its
NR NR ###
cleanliness and condition.

(1) Verify contract.

9 Are parts sequenced at the suppliers facility? (2) Verify broadcasts. NR NR ###
(3) Verify finished goods inventory and documentation.

(1) Dock and incoming material audit sheet.

Does packaging and material handling protect parts from (2) Does WIP protection at supplier have adequate protection to
10 handling damage and contamination? protect parts from damage or contamination until packed. NR NR ###
(3) Are there any PRR's related to Packaging and Handling damage?

(1) Check inventory areas.

(2) FIFO for incoming and shipment parts.
11 Are parts stored in closed and protected areas? (3) Verify documentation. NR NR ###
(4) Interview the Shipping/Logistics/Warehousing personnel.

(1)Manual flame treatment : Intensive or uneven flame treatment

can cause delamination, whitening and off gloss.
Does the operator perform a unverified rework.? (Manual
(2) Paint touch-up : Paint need to be verified with physical
12 flame treatment, NR NR ###
properties(APOPS) and parts shall be approved by GM3660,AAR
Paint touch-up etc.)
and PPAP.
Paint spray facility need to be installed to an isolated room.
Total

F. Preventive Maintenance Program AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

(1) PM Log
(2) PM PFMEA. Separate PFMEA or PM included in part PFMEA?
(3) Is the frequency and instructions for tooling PM linked to the
PFMEA-CP.
Is there a Preventive Maintenance (PM) plan and is it being Enter required evidence (4) Does the instructions clearly specify
1 followed? * cleaning of the cavity and core,
NR NR
description
* proper antirust on the surface,
* ensure smooth movement of the slider, cylinder, ejection pin,
* ensure steady pressure of the cooling system,
* part dimensions meets the drawing specifications..

(1) Check for the first piece approval data and compare with the last
Does the PM team verify difference between First piece and
piece data of the same run.
2 Last Piece and ensure that the part integrity is maintained NR NR ###
(2) Verify that when the tooling reintroduced for production, firs
dimensionally?
piece approval matches with the design data and quality.

(1) Check for unscheduled downtime for maintenance from Takt

board or station downtime log sheet.
Is unscheduled PM driven back in to PFMEA to improve on (2) Verify that this unscheduled downtime for maintenance is being
3 part quality, reduce downtime etc.? reviewed by the leadership. NR NR ###
(3) Irreversible corrective actions are taken/implemented and line
efficiency improved.

PM plan should be developed per the machine manufacturer's

4 Is there a PM schedule for the molding presses? NR NR ###
guidelines. Verify PM plan exists and PM log for machines.

Total

G. Chrome Plated Plastic AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

1) Check process control checksheets

2) Get Barrel size=Diameter of barrel x length - screw size
No regrind Enter required evidence 3) Weigh part convert to volume
1 NR NR
description 4) Shot to barrel ratio= Part weight (by volume) divided by barrel
size

Shot size 40 to 80% of barrel size Check process control set sheet
2 Compare cycle time to process control sheets. Tolerance is +/- 1 sec NR NR ###

Refer to Machine/process set up sheet. Variation should be no more

3 Cycle time NR NR ###
than 1/2 a sec
Refer to Machine/process set up sheet compare it to material
4 Total fill time 4 to 10s NR NR ###
supplier recommended process sheet
1. Verify supplier has pyrometer and used on a regular bases. Check
Melt temperature in upper half of material process
5 operating range. NR NR ###
specification
2. Check cooling temperature to pyrometer

Check process control check sheet. Recommended testing once a

Tool temperature in upper half of material process
6 run NR NR ###
specification
Check to established boundary samples panels/acceptance criteria
 Verification of acidic acid testing
Evidence of a signed off molding process control parameters by
7 plater and resin supplier
NR NR ###

8 Molding Process Optimization NR NR ###

Total

H. Gas assist Injection Molding AUDIT WORKSHEET

EVIDENCE / G
QUESTION: DOCUMENTATION QUESTIONS TO ASK AND WHAT TO LOOK FOR Answer Y OBSERVATIONS
REQUIRED R

Check which type of Gas unit supplier use. Whether supplier uses
Enter required evidence Nitrogen cylinders as source of Gas. If yes, how supplier maintain
1 Source of Gas NR NR
description inventory of gas cylinders. Whether enough spare cylinders available
for production. Check for previous record of consumption.

How supplier ensure that required pressure is available .Whether

Whether Nitrogen Gas generation Unit gives steady flow Gas generation unit have pressure control switch ? If any alarm raise
2 with required pressure ? if required pressure not available at out put line. Check for
NR NR ###
calibration frequency of pressure switch & indicating gauge.

Pressure of Nitrogen at Machine How operator ensure that required pressure of nitrogen is available at
3 Machine ?
NR NR ###

Check Whether supplier ensure quality of air. Oil or water content in

4 Whether Pretreatment of Air being done at N2 generator ? air may damage generator. Recommended air quality is : ISO NR NR ###
8573.1 Class 1.2.1.
Whether moisture content is monitored ? How supplier monitor moisture content of air ? Any alarm indication
5 available if moisture content increases than required ?
NR NR ###
Whether operation parameters available with supplier. Generally
6 Standard operating parameters.
mold manufacture's specify parameters.
NR NR ###

Whether preventive maintenance plan available with supplier.PM

7 Is PM is defined for Gas generation Unit. completed as per plan ?Whether critical spares identified by supplier NR NR ###
& inventory of same available.
Whether PM plan includes check points for Nozzle/Shut off valve/Gas
8 PM of Mold
channels. Whether PM completed as per plan ?
NR NR ###

9 Whether Oxygen analyzer Calibrated recently ? It is recommended that Oxygen analyzer to be calibrated monthly . NR NR ###

Check for type of cooling used. Check how supplier controls cooling
10 Whether cooling fixture used ? of parts. If water cooling is used ,how supplier maintain temperature NR NR ###
of water ?
Total

SCORE

Rating:
Green ≥ 90% / Yellow 70-89% / Red ≤ 69%

Sections Percent of compliance Results score

A. Technical Information availability on this specific
part
7% RED ###
B. Quality System Documentation and
Implementation
0% RED ###
C. Contamination Plan 0% RED ###
D. Process Parameters 0% RED ###
E. Post Molding Process 0% RED ###
F. Preventive Maintenance Program 0% RED ###
G. Chrome Plated Plastic 0% RED ###
H. Gas assist Injection Molding 0% RED ###

If any of the single sections is rated RED, overal audit result is RED with 0% score

Summary score 0% RED Pts Element Scoring

Requirements not met, needs immediate correction
0 SQE to assure actions are in place prior to leaving the facility,
including CS1/2 implementation if necessary
Requirements not met, process acceptable with additional controls in
1 place

2 Requirements met, process has improvement potential

3 Requirements fully met, best practice process in place

NA Not Applicable (does not impact audit score)

Supplier Representative Name with Signature

GM Representative Name with Signature NR Not Rated (impacts audit score)
Process Performance SUPPLIER ACTION PLAN REPORT Rev. 7 1/7/02

Supplier Start Date: SQE

Location Rev. Date: SQE Phone:
Duns Grad Date: Manager:
Commodity Program: Group:
Prepared by: Creativity Team:

G Green - Task Completed on Time

Y Yellow - Task May Be Late
R Red - Task is Late
W White - Task Re-Timed, No Status
B Blue - Task Status is Incorrect / Not Updated
On Track (Bold Box/No Color)
STATUS
Most
Oldest Recent

AUDIT DATE TARGET ACTUAL LAST

ITEM Priority ACTION ITEM ACTION LEADER 1 2 3 4 5 6 COUNTER MEASURES
SECTION OPENED CLOSE DATE CLOSE DATE UPDATE

1
2
3
4
5
6
7
8
9
10

740004930.xlsx Printed: 03/29/2024 Page 5 of 6

Audit form developed by:
Name Department Region Phone Mail
Name Dept

Changes Log:
Date Version Description
04/01/09 Initial Release
4/8/2009 1.0 (1) Objective evidence column cleaned out for onsite auditors comments per new directive.
7/29/10 1.1 Added section D and E and applied lessons learned from past chrome warranty issues
5/27/2011 1.2 Added lines 12-14 on section B to include more quality control checks.
10/10/2011 1.3 Added several updates on behalf of Exterior team.
3/16/2012 1.4 Added line on part conditioning.
27/10/2012 1.5 Added section H
7/12/2013 1.6 Improve logic and practicability of the Injection Molding S-PCPA base on feedback from SQEs audit practice, to make it more eff
10/31/2013 1.7 Added A-5,B-13,C-6,7 and E-12 to ensure effective process audit.