424305780.

xls Checklist Printed 06/14/2019

A. Metrics AUDIT WORKSHEET

QUESTION:
EVIDENCE G/Y
In regard to the Metrics, LOOK FOR Score OBSERVATIONS
REQUIRED /R
Posted record
Is Downtime Analysis by department, Chart updated w/in
1 on the shop
Production Plan vs. Actual, posted? 30 days
floor
Posted record
Is Scrap Analysis by department, Chart updated w/in
2 on the shop
Production Plan vs. Actual, posted? 30 days
floor
Is the Voice of the Customer posted? Posted record
Chart updated w/in
3 (Charts for PPM, # of PRR's and Major on the shop
30 days
Disruptions) floor
Posted record
Is Rework Analysis by department, Chart updated w/in
4 on the shop
Production Plan vs. Actual, posted? 30 days
floor
B. Standardized Work at each operation AUDIT WORKSHEET
QUESTION:
EVIDENCE G/Y
In regard to Standardized LOOK FOR Score OBSERVATIONS
REQUIRED /R
Work,
Elements of Each operation to
At each operation, that has a human
work are have elements
1 working, are the elements of work within a R
identified with posted with order
cycle with times posted?
time and time.
Each operation to
Is the total cycle time identified at each Cycle time at
2 have the cycle time R
operation? each operation
posted.
Diagram Each operation to
showing each have a diagram
Is each operation diagramed showing the
3 element, order showing the work R
operator's path and work order?
of element and order of each
operator's path element posted.
Audit sheets Daily standardized
Is each operation audited to see that
4 with sign-offs of work audits posted R
standardized work is followed?
each review at each operation
Posting of part
Correct part
numbers used
5 Is the Bill of Material posted at each job? numbers being used R
at each
at each operation
operation
A listing of all Each operation to
Is there a graphic showing the required required tools have a graphic with
6 production tools and safety equipment and safety tool and safety R
needed at each operation? requirements at equipment
each operation requirements
An insignia (ie
KPC are
diamond) that
Are Key Product Characteristics identified highlighted at
identifies any KPC at
7 at the station(s) that produce(s) that each operation R
an operation that
characteristic? that effects the
produces the
KPC
characteristic

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Posting within
each
department
Is operator certification posted for each Training Matrix
8 with operator R
operation? posted
names that are
certified for
each operation
Problem
5 Phase or other
solving
problem tracking
Are problems documentation worksheets worksheet for
worksheet posted at
for any customer dissatisfies (PRR) PRR's caused
9 operations where R
posted at the operation where the error by that
errors were made
was made within the last 12 weeks? operation within
and PRR
the last 12
documented
weeks
Agreed upon
completed Sample board with
Are boundary samples present for each
10 component signed-off R
part produced?
boundary boundaries
samples
Job element
within standard
Inspection element
identifying
Are successive checks identified in work documented to
11 inspection of R
elements? review prior
previous
operation
operation's
work

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C. Material AUDIT WORKSHEET

QUESTION: EVIDENCE G/Y
LOOK FOR Score OBSERVATIONS
In regard to Materials, REQUIRED /R
Label with part Part numbers
Are parts storage areas at each operation
numbers at identification at each
1 labeled to show part numbers stored at R
each storage operation where
that location?
location parts are stored.
Part container
Look for stock dates
dates at each
Is First In/First Out maintained at each at each storage
2 operation show R
operation? location for each
oldest material
operation
being used first
Min/Max Overstocking or
inventory label understocking of
Are Min/Max quantities displayed at each
3 at each material based upon R
operation's part storage location?
operation's min/max
storage location requirements
Build-up of
Operator is not
4 Is the operator working ahead? subassemblies or R
over producing
excess WIP
Operations are
Material is not
Is Work In Process minimized? (If balanced and one
be stored
5 operations are not bottlenecks, is one operation is not R
between
piece flow being utilized) overproducing
operations
versus another.
D. Quality System (Method)
QUESTION:
EVIDENCE G/Y
In regard to the LOOK FOR Score
REQUIRED /R
Quality System,
Signals to operators
Error detection
1 Is there any error proofing present? that an error has R
is present
been made.
A test rabbit is
Documented
Are procedures are clear to check and utilized to verify
2 daily audit of R
verify functioning of error-proofing? function of error-
error proofing
proofing
Part measured
Dimensional
3 Verify a part is within specification with production R
discrepancies
gages
Operator instructions
Control Plan
and reaction plan
4 Is the control plan being followed and Operator R
per current control
Instructions
plan located in dept.
Process control and
Are KPC's statistically tracked at the
5 Control Chart capability R
operation(s) that produce them?
improvement

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Calibration
Are Product Measurement Systems Sticker on the Gage tag and how
6 calibrated and work instructions to utilize gage < 1 yr old the operator follows R
the gage present? and work gaging instructions
instructions
E. Environment
QUESTION: EVIDENCE G/Y
LOOK FOR Score
In regard to Environment, REQUIRED /R
Areas to be sized to
Space with accommodate all
1 Are Meeting areas provided? R
chairs members within a
team.
Performance charts,
Department
Organizational wins,
Is key information provided by performance to
2 Organization vision, R
management to the shop floor? business to
priorities and
plan is posted
objectives
Posted team
Meeting
performance and
3 Are team meetings conducted monthly? minutes/team R
actions based upon
reporting
meetings

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F. Quality in Station
QUESTION:
EVIDENCE G/Y
In regard to LOOK FOR Score
REQUIRED /R
Building Quality in Station
Operators
signal for help
Are there visual or audio signals
and support Operators calling for
1 identifying problems found by the R
can receive assistance.
operator(s)?
signal
immediately
Communication
signal for
Is Andon clear to everybody, e.g. location Light Boards, lamps,
2 maintenance or R
and nature of problem? or audio signals
operator
support
Andon's function and
3 Does Andon function without trouble? Function Andon R
response to request
Continuous
Documentation
improvement data
Is Andon tracked and problem solving in with tracking of
4 for line R
place to reduce the number of calls? improvement
stoppage/downtime
plans
from Andon
G. 5-S (Workplace Organization)
QUESTION:
EVIDENCE G/Y
In regard to the Workplace LOOK FOR Score
REQUIRED /R
Organization,
No excess
Things not being
Are only things that are part of the equipment/tools
1 used to produce in R
process existing in the work area (Sort)? or parts present
the work area
in work area
Floor markings Materials in the work
and signs area without
Are things set in order with visual controls
2 identifying designation of what R
present(Set in Order)?
everything in it is or where it
the work area belongs.
Only debris
from the past
24 hours of Leaking equipment,
3 Is the area clean(Shine)? production debris being R
appears collected over time
present in the
work area

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Required cleaning
Housekeeping
materials and their
tasks are
Housekeeping is identified in work locations are
4 defined in the R
standards (standardized)? identified within the
work
workplace
instructions
organization
Audit checklists Shop floor
Does management audit housekeeping
5 and records of documentation and R
and workplace organization(Sustain)?
audits results
H. Management
QUESTION:
EVIDENCE G/Y
In regard to Management, LOOK FOR Score
REQUIRED /R
Improvement
Does Management send messages of goals and postings in a location
1 continuous improvement on the shop objectives that is R
floor? posted in visible/accessible.
department
Problem
communication
Management matrix indicating
Is management frequently on the shop
2 presence in which circumstances R
floor?
work area certain levels of
management
requires notification.
Audit review
area, review Daily meetings
Are there daily performance reviews with data and covering data from
3 R
goals clearly communicated? objectives the customer and
present on the internal audits.
shop floor

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I. Rework/Sort
QUESTION:
EVIDENCE G/Y
In the rework and sorting of LOOK FOR Score
REQUIRED /R
product,
Part labels
Repair materials not
identifying
Are rework materials marked and stored in clearly identified or
1 rework and R
clearly defined areas? located in
defined storage
undesignated areas
of rework
Approved
Are rules and procedures clear when A list of reworks and
2 rework R
rework is needed? procedures for each
procedures
Material flow of
rework back
Inventories of
3 Are rework materials reverified? through normal R
reworks
production
audits
Containment driven
Are countermeasures to problems Countermeasur
4 back to the source of R
managed effectively? e log for rework
error.
J. Machine/Tooling
QUESTION:
EVIDENCE G/Y
In regard to the LOOK FOR Score
REQUIRED /R
machinery and tooling,
Maintenance A log of maintenance
Do maintenance checklist exists for
1 checklist at activity at the R
machinery and tooling?
operation equipment.
At machinery,
Do maintenance trouble log exists and are Time down on
2 an up to date R
they posted at the machinery? maintenance log.
trouble log
During review
No disruptions
3 Are machines running without trouble? are machines R
during review
running.
Control Chart
Are machine control characteristics or out of control Uncontrolled
4 R
tracked/controlled at each machine? signal (Audible equipment
or Visual)

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 424305780.xls Summary Printed 06/14/2019

Supplier: DeComa Duns Code: 246519953 Date: ###

Location: Concord Ont SQE/Team Auditors: K.Capps
Part Desc. Plant Mgr. Craig Matthews
General Motors Shop Floor Excellence Review
Metrics:Information Displayed(Method) Quality in Station(Method)
Downtime Voice of the Customer Visual or audio signal identifying problem found by operator
Scrap Rework Andon is clear to everybody, e.g. location and nature of problem
0 Total Potential 16 0% Andon functions without trouble
Standardized Work @ operation(Method) Andon is tracked and problem solving is in place
Each element of work identified with time 0 Total Potential 16 0%
Total cycle for each operation identified Workplace organization: 5S(Method)
Diagram showing elements and order Only things that are part of the process exist in work area(Sort)
Signed off standardized work audit sheets Things are set in order with visual controls present(Set in Order)
Bill of Material The area is clean(Shine)
Required production & safety equipment graphic Housekeeping is identified in work standards(Standardize)
Key Product Characteristics identified Management audits housekeeping and workplace organization(Sustain)
Operator Certification posted/documented 0 Total Potential 20 0%
Problem documentation worksheet e.g. 5 phase, 8D Management(Method)
Boundary Samples are present Sends messages of continuous improvement
Each operation verifies previous operation's work Are frequently on the shop floor
0 Total Potential 44 0% Daily performance reviews with goal clearly communicated
Material(Material) 0 Total Potential 12 0%
Parts storage area of inventory identified, e.g. shelves labeled Rework / Sort(Method)
First In/First Out is maintained at operation Rework materials are marked and stored in a clearly defined area
Min/Max quantities are displayed at storage locations Rules and procedures are clear when rework is needed
Operator is not working ahead Rework material is reverified
Work in process is minimized (one-piece flow) Countermeasures to problems are done effectively
0 Total Potential 20 0% 0 Total Potential 16 0%
Quality System (Method) Machine/Tooling(Machine)
Display of error proofing exists Maintenance checklist exists machinery and tooling
Procedures are clear to check and use error proofing Machine trouble log exists and is posted at the machine
A part is verified within specifications Machines running without trouble
Control Plan is being followed Machine Control characteristics are tracked at operation
Key Product Characterisitic data is on the floor 0 Total Potential 16 0%
Measurement systems; calibrated with opr.instructions % Pts Summary Status

0 Total Potential 24 0% 0% 0 Displayed Metrics RED

Environment(Environment) 0% 0 Standardized Work at each operation RED
Meeting areas are provided 0% 0 Material RED
Key information is shared by mgmt e.g. Business perf and wins 0% 0 Quality System RED
Team Meetings are conducted at least monthly 100% 0 Environment GREEN
0 Total Potential 12 0% 0% 0 Quality in Station RED
0% 0 Workplace Organization RED
0% 0 Management RED
0% 0 Rework / Sort RED
Pts Element Scoring 0% 0 Machine RED

0 Element not in place; no evidence of plans to implement 0% 0 Overall RED

1 Element is not in place but a plan to implement is documented Summary Scoring:
2 Element is in place but it is not being followed Green 80%
3 Element in place but not followed at each job or all the time Yellow 60-79%
4 Element is in place and it is being followed Red <59%

Rev 7 4/11/01
 SUPPLIER ACTION PLAN REPORT 9of 13

Supplier Start Date: 07/25/01 SQE

Location Rev. Date: SQE Phone & Fax #:
Duns Exit Date: SQE Email
Commodity Manager:
Prepared by: Group:

"Support" is defined as GM Management Level or Group needed to remove item roadblock A=NAO/WWP, B= Group Director, P=Purchasing , S=Supplier Development, E=Engrg
"Color Codes": Green - Task Completed on Time; Yellow - Task May Be Late; Red - Task is Late; White(W) - Task Re-Timed, No Status; Blue - Task Status is Incorrect / Not Updated
TOTAL TOTAL COLOR CODE No Color - Task on Track
EXIT C
REQ.
# 0 0 U
G Y R W B
R
R
S
E
U PAST STATUS
DATE TARGET ACTUAL N
ACTION P LAST T HISTORY
ITEM ACTION ITEM P OPENE CLOSE CLOSE COMMENTS
LEADER O UPDATE (EARLIEST TO THE
R
D DATE DATE S LEFT)
T
T
A
T
U
A. Metrics S

A1
A2
A3
A4

B. Standardized Work at each operation

B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
C. Material
C1
C2
C3
C4
C5

Print Date:06/14/2019 Rev. Level: 8

File Name: 424305780.xls Rev. Date: 5/9/01
 SUPPLIER ACTION PLAN REPORT 10of 13

Supplier Start Date: 07/25/01 SQE

Location Rev. Date: SQE Phone & Fax #:
Duns Exit Date: SQE Email
Commodity Manager:
Prepared by: Group:

"Support" is defined as GM Management Level or Group needed to remove item roadblock A=NAO/WWP, B= Group Director, P=Purchasing , S=Supplier Development, E=Engrg
"Color Codes": Green - Task Completed on Time; Yellow - Task May Be Late; Red - Task is Late; White(W) - Task Re-Timed, No Status; Blue - Task Status is Incorrect / Not Updated
TOTAL TOTAL COLOR CODE No Color - Task on Track
EXIT C
REQ.
# 0 0 U
G Y R W B
R
R
S
E
U PAST STATUS
DATE TARGET ACTUAL N
ACTION P LAST T HISTORY
ITEM ACTION ITEM P OPENE CLOSE CLOSE COMMENTS
LEADER O UPDATE (EARLIEST TO THE
R
D DATE DATE S LEFT)
T
T
A
T
D. Quality System (Method) U
S
D1
D2
D3
D4
D5
D6
E. Environment
E1
E2
E3
F. Quality in Station
F1
F2
F3
F4
G. 5-S (Workplace Organization)
G1
G2
G3
G4
G5
H. Management
H1
H2
H3

Print Date:06/14/2019 Rev. Level: 8

File Name: 424305780.xls Rev. Date: 5/9/01
 SUPPLIER ACTION PLAN REPORT 11of 13

Supplier Start Date: 07/25/01 SQE

Location Rev. Date: SQE Phone & Fax #:
Duns Exit Date: SQE Email
Commodity Manager:
Prepared by: Group:

"Support" is defined as GM Management Level or Group needed to remove item roadblock A=NAO/WWP, B= Group Director, P=Purchasing , S=Supplier Development, E=Engrg
"Color Codes": Green - Task Completed on Time; Yellow - Task May Be Late; Red - Task is Late; White(W) - Task Re-Timed, No Status; Blue - Task Status is Incorrect / Not Updated
TOTAL TOTAL COLOR CODE No Color - Task on Track
EXIT C
REQ.
# 0 0 U
G Y R W B
R
R
S
E
U PAST STATUS
DATE TARGET ACTUAL N
ACTION P LAST T HISTORY
ITEM ACTION ITEM P OPENE CLOSE CLOSE COMMENTS
LEADER O UPDATE (EARLIEST TO THE
R
D DATE DATE S LEFT)
T
T
A
T
I. Rework/Sort U
S
I1
I2
I3
J. Machine/Tooling
J1
J2
J3
J4

Print Date:06/14/2019 Rev. Level: 8

File Name: 424305780.xls Rev. Date: 5/9/01
Procedure to use computer to fill out forms

Use blank checklist on floor and fill in score and comments

Fill in checklist 1st on computer, this will automatically fill in and calculate the summary sheet,
comments on checklist will automatically become action items on the action form.

If the comments don't fit in the action item cell adjust the row height by: move cursor to row number
slowly move cursor to the bottom of the row number to line between rows, the cursor will change
from a large plus sign to one with lines, when this happens quickly double click the left button.

Rows that have no actions items or comments that you don't want to be action items can be hidden or deleted:
Move cursor to row number, click the right mouse button, select either hide or delete from pop-up menu

The info filled in at the top of the Summary sheet will automatically fill in on the Action Form.
or deleted:
op-up menu