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[Music]
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this series of videos has been filmed in
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an atf1 16949 certified supplier who is
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involved in the manufacture of a wide
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range of rivets used for automotive and
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non-automotive
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applications they also design a
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manufacture equipment used in Rivet
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insertion the video shows extracts of
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simulated atf1 16949 audits focus on the
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organization's quality management system
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processes watch this video and see if
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the auditor is undertaking the audit
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effectively as always we welcome
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feedback and comments Dave I understand
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that you can help me so I've just been
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auditing the process of how you receive
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uh the steel wire y um I've looked at
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batch number 2083
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and they pointed me in your direction to
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talk about the
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verification of the the material uh
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quality that's fine so could you give me
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an overall uh explanation first of what
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you so an overall explanation straight
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away is is this is all one delivery
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that's come today um this morning um
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it's wire batch 2077 which is already um
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a wire batch that we have in stock and a
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new wire batch today which is quite
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handy for what we're doing here is 2083
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this is the one that I saw out there
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this the one there so basically what
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what we do we they come wrapped in um
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plastic we take the plastic off and on
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attached to every coil is is a sample of
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wire for that for that coil so we take
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that off and bring it into the into the
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lab here yeah um label it all up
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ourselves and basically we just cut it
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down and cut a small piece off and then
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what we do then we cut a mount them on
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the machine over there and we uh polish
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them we grind them down first on the uh
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piano discs which are 200 and 1,200 and
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then onto the polishing pad over there
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and then we decab them over on the
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microscope over there right so that's
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more the physical uh way of doing it
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just explain why the six samples there's
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there's six samples here because there's
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six um coils in that um okay one sample
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per coil yeah it's one sample per coil
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so there was six coil batch um uh coil
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coils sorry on that wire batch and on
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this one here which is already an
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existing watch which which is slightly
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easier U because we don't have to do the
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ttile on that but because this was a new
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wire batch that we had in today we've
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had to do a ten tile on it to test out
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the mega pascals and and the strength of
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of the uh of the wire uh which is passed
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here cuz it needs to be between 540 and
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590 megap pascals and it's pass today
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matches yeah that matches the control
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plan so let let's concentrate on the the
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tensile strength first there okay so as
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the control plan says 540 to
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590 what was the actual reading the
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actual reading for this today off coil 3
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it is so it's wire batch 2083 the coil
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number is
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32718
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sl3 um and we have to put in the wire
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diameter which I I I measure all the
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wire diameters before I go to make sure
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that they're is spe um because the wire
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diameter for this patch need to 5.5 to
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5.55 which is all on the actual um CFC
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yeah and again that matches a control
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plan um which is got all of our chemical
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analysis on here as well which is is
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part of the heat treat number there so
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we we just check it with the
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specifications this this is provided by
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the supplier this is supplied supplied
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by the supplier yes so we just make sure
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that it is the chemical analysis is
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right we do all that before we go to um
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do the tensile so we we have to put the
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wire diameter in for the yeah excuse me
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for the um tensile and is the yeah is
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the T test done in here h no it's in
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equipment oh okay so we'll we'll we'll
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follow that in a minute yeah it's the
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other side of Cu I want to verify the
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calibration of that test so so basically
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then what we do it's it's we work at a
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10% um uh thing so so with this being
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six coils we only need to do one so if
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it's anything over 10 coils so say for
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this one if this hadn't been this wire
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batch 2077 with it being 11 coils that's
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just out of the 10% so we'd have to do
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two samples then and take them down to
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10
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yeah but with this only being a new
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batch and being six we just had to do
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one so this one passed today and it had
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to be between sorry going back to 540 to
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590 megap pascals and it's 547 so that's
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that's great perfect and what action
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would you take if it didn't pass and we
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then we then would flag it up to Steve
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Davenport who is um in charge of that so
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yeah and
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also basically send an email to everyone
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everyone else and and that's sqa isn't
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it Steve okay so we will follow that
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witha does that happen very often uh no
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no no not not very often again that
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matches the records that I saw uh when I
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it it does occasionally but but what we
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do we take two samples down per coil so
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if one fails we we test it again and if
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they both fail that's when we flag it up
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to speed and then it gets Blue Label
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then yeah and just going back one step
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you said is it the
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decarbonization test you do what's the
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acceptance criteria for that um it's
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it's well it's on the wall here it's the
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Martin site that we have there that we
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have to have that um theing for that
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that that that texture that that um and
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that's done using the Microsoft yeah
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that's done using the Microsoft so what
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we do we we once we've taken it down the
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grinder we've polished it and we've um
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dipped it in acid it's it's a 5% nitric
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acid mixed with methat Spirits um clean
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it clean it with methyl Spirits dry it
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out and check it on there and that would
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show the grain structure the reason that
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effectively yeah okay and again with
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this batch how do we record the result
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of that deiz basically yes so um there's
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there's P for pass obviously f for fail
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so this this at the moment is a work in
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progress um by wbat 2083 the visuals
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have all been fine so the visual is when
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we get this wire back sample in here but
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it's also when we take the plastic off
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the off the wire in the warehouse to
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make sure that the um that the wire is
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isn't Rusty hasn't got any score marks
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in it hasn't got any scuffs in it hasn't
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been knocked by the you know by another
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coil or or in transit at all so that's
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that's all fine yeah that's fine so what
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I'll do then is I will follow the audit
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Trail through to the tensile tester um
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and verify the calibration of that but
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no your explanation was clear thank you
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very much no problem in this video the
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auditor is following an audit Trail to
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verify the receiving inspection of the
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wire that is used in the rivet
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manufacturer process the checks are done
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in the internal
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laboratory this gives the opportunity to
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verify the internal laboratory scope the
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inspection and the test methods and the
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competency of the laboratory
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Personnel the good thing is that the
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auditor ask the audit to give an
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overview at the process at the beginning
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the audit explained that there are six
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samples that are verified in this case
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matching the number of coils within the
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batch the auditor also made good use of
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the control plan during this part of the
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audit the audit here explained that for
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the tensile test the number of coils
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checked depends on how many coils in the
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backat he explained that if there are
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less than 10 coils only one coil is
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check
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but if there are more than 10 for
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example between 10 and 20 two samples
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are taken the auditor asks what happens
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if a coil fails the tensile test
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although the auditor answered this
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verbally there is also the opportunity
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to verify the reaction plan that should
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be defined within the control plan the
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auditor establish that the tensile test
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is done in another area within the
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organization and he stated that he would
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follow the audit Trail to this later in
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the audit to verify the calibration
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status of the
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equipment the audit then moved on to the
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decarbonization test which the audite
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explained
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verbally here there would have been the
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opportunity to look at the inspection
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and test work
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instruction also it was not clear
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whether the test was an attribute test
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or a variable test that was undertaken
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using the microscope in either case the
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auditor should verify the acceptance
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criteria the calibration of the
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microscope and the measurement of system
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analysis for this type of
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equipment it was also evidence from the
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audit that the organization relies on
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the supplier certificate of the analysis
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of many of the Mater material properties
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in this case this would relate to ATF
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requirement
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8.4.2 point1 type and extent of control
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and this requirement has been
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supplemented by sanctioned
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interpretation 7 which added the
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requirement where characteristics or
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components pass through the
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organization's quality management system
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without validation and control the
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organization shall ensure that the
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appropriate controls are in place at the
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point of
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manufacturer this gives the opportunity
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for the auditor to follow the audit
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trail to the supplier
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selection any supplier monitoring that
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is done and any supplier audits that
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have been undertaken to verify the
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controls related to the pass through
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characteristics are been managed
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effectively
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[Music]
