TITAN PNEUS DO BRASIL LTDA

PRODUCT & PROCESS QUALITY AUDIT Based on Audit Revision 0

DATE:

AUDIT TEAM:

NAMES:

SIGNATURES:

_______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________ _______________________________________

___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________

Product & Process Q

Area Week

Training & Communication Raw Materials, Mixing & Labs. Component Prep Truck Rear Farm & OTR Curing & Final Finish Monitoring & Lab. Testing Warehouse & Shipping Engineering Requirements & Calibration

7/18/2011 19 e 20/7/11 21 e 22/7/11 7/25/2011 7/26/2011 27 e 28/7/11 7/29/2011 8/1/2011 8/2/2011

External PPQA New Tire Development

8/3/2011 8/4/2011

Total

Outghoing Quality Audit

uct & Process Quality Audit - Titan Pneus do Brasil

Nr of Aplic. Items % OK N N C

8 (5) 40 (22) 54 (19) 27 (16) 34 (16) 50 (25) 15 (9) 8 (8) 31 (0)

14 (0) 10 (0)

291 (120)

neus do Brasil
Pending Nr of Opportunities Pending

Product & Process Quality Audit - Titan Pneus do Brasil

Area Week Nr of Aplic. Items % OK N N C Pending Nr of Opportunities Pending

New Tire Development Training & Communication Raw Materials, Mixing & Labs. Component Prep Truck Rear Farm & OTR Curing & Final Finish Monitoring & Lab. Testing Warehouse & Shipping Engineering Requirements & Calibration External PPQA

10 8 40 54 27 34 50 15 8 31 14

Total

291

Outghoing Quality Audit

CORREC Reviso: 01 NR NC Opp Area Question Nr Question (check list)

CORRECTIVE ACTIONS

Description of nonconformity or opportunity for improvement

Root cause and correvtive action

Responsible

Final Date

Status / Comments

Area

SubArea

Ques#

Question

No existe no check list de offtake

Tire Release System.

Do tire releases meet requirements of GQMTS 19R and the appropriate S19R* (Subsections depending on specific product line)?

4.1*

4.2

Is there a system for planning tire release activities?

4.3

When developing a new tire, is the necessity for a new bladder size (curing and building) considered?

4.7

Are all tires released through a formal release meeting?

4.8

Is there a release package?

4.1

Is there a system to follow the performance of new tire codes and tune as required?

4.11 4.12

Are new tire standards set so that uniformity performance is equal to or better than plant average for similar size and type of tires? Are corrective actions in place as required?

4.14*

Is there verification that mold stamping is correct for new tires?

4.16

Is there a system to ensure that experimental tires not meeting regulatory, corporate and/or customer requirements are dispositioned correctly?

GUIDELINES

GQMTS 19R (and S19R* subsections for specific product lines) specifies the different releases applicable to new tires project. They give detailed information on the tests to be performed and their frequency. Only tires meeting all the release criteria can be introduced into the manufacturing process. Are all steps of the process followed?

Must include planning of all projects development as well as individual projects activities with promised date for items on project list. There should be evidence of a visual display board (or equivalent system) detailing tire builds & ship dates (SOP & Buildwires). Plant commitments to the visual board (or equivalent) should be communicated to the Region.

Is bladder fitment analyzed during feasibility assessment ? Review records of manufacturing feasibility.

The release procedure (GQMTS 19R) calls for a local release committee including a regional dev. Repr. for "A" releases. This committee has to meet when all test results are on hand for review. The formal signed release is given by the committee based on the results. OTR releases conform to GTC* A (Dept. 460E) requirements for tire release.

All original test data + the release documentation will be compiled in a package and kept on record. This info is used as baseline.

Special follow-up of a newly introduced tire code is required per QAI-2017 All Tire Lines: Production Tuning/Monitoring Procedure. This is done in the minimum of 2 weeks tuning phase. Records of the performance and tuning items must be available with the tire code specific information.

Is documentation available? If below plant average is there regional approval to run the tire. Review records at the end of tire tuning. Review documented evidence as required prior to new product being released to production. A record of verifying mold and tire stamping to the Stamping Drawing and Corporate Design Specification must be included in the New Tire Release Package. For OE tires with special stamping requirements, verification must also include conformance to the OE drawing. or OE customer stamping documents (Reference GQMTS:S19R)

Review documented evidence of plant system to insure tires leaving the plant have legal DOT serials and tires not meeting regulatory, corporate and/or customer requirements are dispositioned correctly.

Area

SubArea

Ques#

Question

Training & Communication

1 Is there a machine operator certification system available?

5.1.1A

Is there an initial machine operator certification system available for contract associates (non-permanent labor)?

5.1.3

Is there a system to recertify or verify operators on an annual bases (SP procedures)?

5.1.6*

Are critical elements which effect final product identified in the training material for each area? Is there a list of certified operators by machine type? Do training manuals exist for all functions in the tire rooms/curing/final finish/ etc? Are there designated labor trainers for each job or operation

Is there a process to communicate quality issues to all associates as appropriate?

GUIDELINES

Is there a documented training certification system Is there a formal signoff (Labor Trainer/manager) Randomly select an associate from each Business Center & Verify certification/training records Are Labor Trainers included in the certification program? Is there a documented training certification system? Verify requirements for certification Is there a formal signoff? Randomly select an contractor from each Business Center & verify certification / training records Are assigned personnel included in the Certification Program? Verify documented recertification or verification program The frequency for recertification/verification must be triggered by an annual occurrence, i.e. service date, birthday, etc. Check if recertification or verification frequency is being followed (random check from each Business Center) Review OBT material/ contractor training to verify the critical elements are included. Is there a formal approval signoff before using new training material? Verify list of Certified Operators by machine type Is the list available for Area managers to fill vacancies? Does the list show certification date? When is recertification due? - Verify manuals exist for all areas. Have they been instructed on the training systems & procedures? Have they been instructed on the proper training method (4-step method)?

Is there a Communications Business Plan? Is there a documented process to communicate quality issues? Verify records to confirm quality communications are occurring. Is there a system to measure the effectiveness of the communication?

Area

SubArea

Ques#

Question

Raw Materials, Mixing & Labs.

Mixing/Qual & Labs Mixing/Qual & Labs 6 Are routine audits being performed in the Mixing area? Is the CAR system used to notify supplier concerning issues of nonconformance and is cost assigned systematically? Is there a procedure in place to evaluate raw materials and second sources? Is there a documented system to receive, store and release raw materials? Are age limits followed?

6.1.3

6.1.4

9 10 11 12

Are release procedures being followed? Are released materials correctly identified? Are materials awaiting disposition correctly identified? Are incoming pallets of halobutyl and butyl marked or identified as being incompatible? Are storage conditions adequate and free from contamination?

13

14

Are incompatible materials separately stored in a well identified area? Are only specified compounds, raw materials being used? Is there a procedure to introduce new compounds and compound changes? Is there a system to insure that changes to mixing specifications are implemented correctly?

6.2.2 6.2.3

6.2.3a

6.2.3.b Is automatic discharge system in place 6.2.4 Are the correct workaway and disposition procedures being followed for off test compounds/components? Are the procedures for BB and pigment room scales quick checks by operators being followed and documented?

New

6.3.2

Are all scales capable of controlling the weighments within specified tolerances?

6.4.1 6.4.2

Is there a documented raw material traceability system? Is the traceability effective ?

6.4.13

Are appropriate storage being used (no

wood!) and are they

contamination free ?

6.2.14* Are banbury cleaners scheduled as required and run as scheduled? 6.4.15 Is dust-collector dust reworked as per specification?

Mixing/Qual & Labs

Mixing

15 16 17

Are the correct quality requirements available to the operator? Are requirements for machine set-up correctly identified? Is machine set-up being done correctly with appropriate tools?

18 19 20 21

Are age limits followed? Are all the weighments controlled within specified tolerances? Are incompatible materials and compounds handled correctly and kept separate? Are non-productive and productive compound for butyl innerliner and coverstrip marked with a red stripe? Are all temperature and pressure gauges set to spec? Are the correct blend bags being used? Are bags closed correctly? Are blend bags loaded on the charging conveyor properly? Are all the specified compound tests being carried out? Is plant following GQMTS procedure for handling soft/NO cures?

22 23 24 25 26 6.5.1*

6.5.7

Are compound physical properties within the specified limits?

6.5.8

Is Rheometert properly calibrated and documented accordingly?

6.5.9 Mixing/Qual & Labs

Are the minimum number of banbury samples for all compounds being taken per skid? Is there evidence that specifications and run cards are being followed by associates?

General

27

GUIDELINES

Is there documentation to verify these audits are performed on a regular basis? The plant must have a system to record supplier non-conformance. CARs for the plant can be viewed as well as the Corrective Action Plan. Refer to QAI 2205 Review in SIS CAR CAR reports CAR cost summary Review plant system and documentation to record the evaluation. Procedure must have a documentation showing materials authorized to be used in the plant ("approved material list") with reference to the last evaluation. You must have documentation on your process to receive, store and release raw materials. The documentation must incorporate FIFO release or it is "NO". You must have age limits assigned for all raw materials equal to or less than the Corporate Spec. Corporate age limits are located on the web (http://techweb/MaterialSpecs/agelimits.pdf). A gatekeeper (system or person) is required to ensure limits are followed. Randomly selected raw materials must be within age limit spec. Documentation of the release procedure is required (item 1 above). The operators in charge of identifying released materials must know the system. Randomly selected materials in production use must show they are probably released and within age limits. In storage and mixing production area, randomly checked released materials must have proper release ID (green stripe, OK Tags, Stamp, etc.) and proper material code. There must be an area assigned for out of process raw materials (out of spec, overage, contamination, etc). The current status of a raw material must be easily identified according to the plant system. All incompatible rubbers must have at least one red stripe on each skid. This applies to material as soon as it is received - or clearly identified as incompatible. Raw materials should be stored in a covered area to prevent contamination. The storage area requires good housekeeping of wooden and cardboard pallets, strapping, etc. Materials stored in an open area outside without adequate covering result in a "NO" answer. This area should have a sign stating only incompatible rubbers are stored here. It is preferred that this area have a colored border painted on the floor/poles/walls to further identify it. There should be two areas (one in the warehouse area and one in the staging area by the mixers) otherwise it is a "NO". All materials must be properly identified and match the run card spec exactly. A trial or temporary spec is required for deviations. Review procedure and records. Does it comply with requirements of

GQMTS S19Q1

A system for mix spec changes must include: 1) How the new spec is introduced to the mixer operator and scheduler, 2) How the old spec is removed, 3) a method to record when the mix spec was active in production. The spec changes must incorporate bag spec. 4) There should have a double check for all specifications, made by QTECH. All mixing setup must include max mix time and temperature over-ride GQMTS P09C, CTI-055-11-00287 There must be designated area for out of process (nonconforming material) and NO CURES. Workaway procedures must follow

GQMTS: S09E & P09E or prohibited by a booksheet notes. Verify plant's procedure. Check reformulation
There must be a procedure for deadweight checks for mixer conveyor, carbon black scale, oil scale and pigment scales and documentation is required showing that it is being followed. A random check may be done to confirm the last check was accurate. Rubber, oil, carbon black and pigment tolerances must be available to the operator and all materials on a random batch must be

(GQMTS: S09C and P09C). Scales not meeting GQMTS tolerances must have a completed capability study, plans to upgrade or replace existing scales, and authorization from Regional Qtech or the appropriate Tire Technology Product Group allowing use of existing scale.
within tolerance. If there is a traceability system, the answer is "YES". An effective traceability system must allow compound to be traced to what raw materials (excluding bulk oil and black) were used into each run of compound. -Take a compound and trace all materials back to which lot was used, age upon use and when it was r Visually inspect the skids being used in process for raw materials and compound to see they are clean (no rubber stuck on them)

wooden skids are used in mixing area, automatic "NO". This also applies to bins for preweighed bags. They must be clean and in good condition. Look for all types of FM in banbury area.
and no major damage (torn metal due to truck damage, broken side-rails etc). If Banbury Cleaners needs to be run as per Review if in accordance with GQMTS:

GQMTS: P09C, S08 for incompatible stocks. S09I

The operator must provide the following: 1) the schedule he is working from, 2) a run card (paper or electronic) showing the compound name and serial, all raw materials (with tolerances), mixer RPM, ram pressure, ram raise times, oil injection time, carbon black time, surge time, drop temperature, drop time. Some of these may be set by the control room in which case they should be checked there. Is set up card (electronic or paper), available at the Mixer? Is the set up card completed according to specs & tolerances. Check for calibration of appropriate tools where applicable, (pressure gauges, temperature gauges, etc) . All raw material age limits must be followed as well as age limits for blends, preweighed bags, non-productive rubber, scrap, etc. Plants without age limits for blends and preweighed bags must put "NO". Age limits for non-productive rubber, scrap and other miscellaneous materials are recommended, but not required. Rubber, oil, carbon black and pigment tolerances must be available to the operator and all materials on a random batch must be within tolerance. There must be a separate area for incompatible compounds to be stored. They must be marked with red on the skid and cleaner batches are required before and after an incompatible run. Rubber compound should be marked with colored identification. With the ram pressurized, the gauge should agree with the mixing spec. Confirm that the oil is injected at spec temperature and the batch is dropped at the correct temperature. The two thermocouples should read within 15 degrees F or this is a "NO". Is there adequate documentation to verify bags are from an approved source, are the proper gauge and have the correct melt point. Bags are not knotted when loaded into mixer. If knots are used to close bags, they are cut out prior to loading on charging conveyor. Bags are to be loaded in the middle of the batch to avoid hanging on the rotor or ram. Each type of compound requires specific release and low frequency tests. Each compound must meet these requirements. Review plant procedure and verify against GQMTS P09E. Compound physical properties are within the PPS limits and release limits (Rheometer 191C/200C). If release properties are consistently failing, the answer is "NO". If some low frequency testing is failing and there is a plan to bring them back in spec the answer is "Yes". If no plan, the answer is "no".

QAI2003 which includes use of calibrated torque standard, PCPS plugs (ODR) and meeting the QA Premonth limits. For RPA, calibration should be done per GQMTS: P09L using calibrated torque standard, and meeting QA limits. Verify calibration frequency and records. Sampling, either automatic or manual, to conform with GQMTS S06. 100% for functioning automatic computer controlled systems; 120% for all other systems.
For the Rheometer, calibration should be done per Question operators, review equipment set-up/measurement documentation, compare run card to equipment settings.

Area

SubArea

Ques#

Question

Component Prep
Comp Prep Comp Prep 28 Are routine audits being performed in Component prep areas?

Comp Prep Extruders

29 Does your PH level spec comply with specification ? 30 Does your % suspended solid spec comply with specification? 31 Does your % dissolved solids spec comply with specification? 32 33 34 7.1.1 * 7.1.2 * 7.1.3 7.1.13 7.1.14 Do the alert / shutdown limits comply with specification ? Are running cards posted at machine and being followed? Identification of extrudates? Do you have a QTECH procedure for regular inspection of all extruder cooling lines? Is there documented evidence that the tank has been cleaned when required? Is there a cooling water temperature control system? Is water hardness audited at the frequency specified in Section 10N of the GQMTS? Are the limits for % solids established in relation to the level of water hardness as per GQMTS section 10N?

Is there a system approved by plant QTECH to maintain consistency of 7.1.18 workaway for all compounds where workaway at the extruder is authorized? 7.1.19 Is there a system to correctly identify extrudates? Is the system being followed?

7.1.20 Cement application, storage & housekeeping?

7.1.21 Have skivers been maintained and are they in good working condition?

7.1.22 Are shrinkage checks done on a routine basis?

7.1.24

Is there a compound traceability system for the extruder and is it effective?

7.1.26 Is there a system to pre-heat dies prior to use?

Extruders - Booked Components

7.2.1 7.2.2 7.2.3 7.2.4 Is component length within tolerance? (minimum 3/run) Is component weight within tolerance? (minimum 3/run) Is component width within tolerance? (minimum 3/run) Is component contour within tolerance?

Mill Practices
7.3.1 7.3.4 Comp Prep 35 36 37 38 Are mills properly loaded? Are the cooling channels of the mills functioning per specification?

Gum Cal

Are compounds identified properly? Is compound age specified & observed? Are running cards at machine and being followed? Is the calendered sheet released according to spec?

7.4.5 7.4.7 7.4.8 7.4.9

Is there a compound traceability system at the gum calender and is it effective? Are widths of calendered sheets correct at the gum calender? Are gauges of calendered sheets correct at the gum calender? Are cooling cans and/or Sandwik belts condensate free?

7.4.10 Are calendered sheets identified correctly at the gum calender? New item Comp Prep Resume of 7.4.11/12/13 Cutters 7.4.X 57 58 59 Is machine set-up specified and being followed? Are treatments identified properly? Is the running card available at the machine and being followed? Is identification proper? (Treatment and ply)

7.8.4 7.8.6 7.8.7 7.8.9

Is treatment / ply traceability adequate at the cutter? Is treatment / ply angle correct at the cutter? Is treatment / ply splicing correct at the cutter? Are gum strip/squeegee applications controlled properly at the cutter?

7.8.12 Is treatment storage adequate at the cutter? Comp Prep Bead Winding 60 61 62 63 Is bead diameter checked / documented? Are beads properly identified? Are marking paint and cements properly released, ID'd & stored? Is bead compound (strip stock) retested (rheometer) prior to use? Is the running card available at the bead builder and is it being followed? Is wire coverage good at bead winder? Is there a good traceability system for beads going to tire room?

7.9.1 7.9.3 7.9.6

7.9.10 Is bead wrapping done properly and as specified? 7.9.12 Is bead winder equipped working& broken/missing wire detectors? Are all required radial tirewith (consumer MRT) Tire Building Machine Process Control System Checks (to be detailed upon completion of 7.9.19 Process Control QAI) being made? Comp Prep General 64 Is there evidence that specifications and run cards are being followed by associates?

GUIDELINES

Is there documentation to verify these audits are performed on a regular basis? Is spec posted? Are checks being done according to the stablished frequency? Are results available to review? Are the results inside the spec range? Is there evidence of corrective action? There must be a continuous monioring device, including alarm system. Is spec posted? Are checks being done according to the stablished frequency? Are results available to review, incluiding correlation studies in case of using na indirect measurament method? Are the results inside the spec range? Is there evidence of corrective action? Is spec posted? Are checks being done according to the stablished frequency? Are results available to review? Are the results inside the spec range? Is there evidence of corrective action? There must be a continuous monioring device, including alarm system. Are procedures in place if alert limits are exceeded? Are components held for disposition? There must be evidence/records. Are the latest revisions being displayed- Are the spec being religiously followed Is the spec for identification available Is the marking legible at all time The procedure must be in agreement with GQMTS 10N requirements and must have assigned responsibility and documentation. Review records to verify tank cleaning frequency? The tank must be inspected during the audit. Is there sufficient capacity to allow for component cooling? Spray heads working properly? Cooling water not exposed to outside for cooling? Are results available for review? See % solids/water hardness in GQMTS

section 10N. Are components held for disposition if spec limits are

exceeded?
Formulas must be available and in compliance with GQTMS S09E. Review records to determine if workaway percentages are consistent over time and match the plant formula. Are all extrudates identified? Identification must include part number and age status.

Is the cement properly identified? Is the correct cement being used? Is the cement being agitated as specified? Is the tread skive fully covered with cement as required? Is cement age limit being followed? Are the cement containers being cleaned and changed regularly? (Reference:

GQMTS: S05) (For plants that don't have cements this question is N/A.)

Is there a capability study? Is corrective action taken based on capability study? Is the skiver running smoothly? Is skived surface appearance good? Every time the knifes are changed or a maintenance is done at the skiver, the skived angle should be validated by the QTECH Monitor. Is the frequency specified? Is the check done to the specified frequency? Is the corrective action being taken and documented?

Is the tag retention system available and is being followed? Is correct identification on the tags and date of manufacture ? Are all batched-off compounds properly identified? Is the component traceable back to a run at the BB? Is the preheater available? Is it running at the appropriate temperature? Where die cabinets are used all active dies must be

kept in the heated cabinet. (GQMTS: P10E)

Review records for all Legal / Monitoring testing samples that did not meet spec. Is there evidence that corrective action was initiated? If automatic system are available and in use, the 3 per run is waived. Is correct weighing scale in use? Is scale calibrated at specified frequency? Is component weight checked at specified frequency? Are weights taken documented? If automatic system are available and in use, the 3 per run is waived. Is correct measuring tape used? Is frequency of component width check followed? If automatic system are available and in use, the 3 per run is waived. Is the LMAC or profiler available and functioning? Are components released by contour? Is contour of released components within spec? Without LMAC, minimum of 1/cavity/run.

Is the correct compound used? Is correct identification on the tags? Is there a tag retention system and does it work properly? Is all batched-off compound properly identified? Is lab approval stamped on tags for plants with out ASRS? Are mills being acid cleaned and spray pipe checks done on periodical basis? Are checks documented? Correct compound used- Correct identification on the tags- Is the tag retention system properly working- All batched-off compound are properly identified- Lab approval stamped on tags Is the age limit specified on the running card- Is the time/date stamped on the tag- Is the system being followed Is latest revision of running card available on machine- Is it being followed Is spec with latest revision available- Correct wind-up temperature, gage and width to the specification Is the tag retention system available and is being followed? Is correct identification on the tags? Is lab approval stamped on the tags? Is all batched-off compound properly identified? Are defective components being held-up at specified location? Is the compound easily traceable? Verify treatment widths are within spec and are made and recorded using correct measuring tape. Is the Randall Stickney gauge or similar equipment available and is being used to measure gauge? Are gauges taken recorded? No condensate visible on the cans or on the Is ID (date/time) stamped on the tags? The set-up should be available. Look for records to evidence it is followed. Measure a material sample. ID Tags available and in use- Date and time properly stamped Running cards visibly displayed- Running cards of the latest revisions- Running cards being followed Is the identification correct

Sandwik belt's surface.

Is the treatment traceability system available and is being followed? Is correct identification on the tags? Is there a procedure to check angle? Are checks documented? (see GQMTS: S03B for tolerances) Is specification for splicing available? Is it being followed? Is corrective action taken and documented? (see GQMTS:

S03B

for tolerances)
Are gumstrip dimension correct? Is the application correct and wrinkle free? Is the treatment storage adequate and does it enable FIFO system? Is Bead Diameter Check tool available- Is it in use- Are checks documented Is identification system available- Is it being followed Are they properly specified and released- All paints have proper ID and properly stored Is the test being done- Test result are documented Are running cards visibly displayed? Are running cards of the latest revision? Are running cards being followed? Is coverage being checked across the width? Is corrective action taken and Is the traceability system available? Is it being followed? Is the specification available to the operators? Is it being followed? Verify broken/missing bead wire detectors are installed and working on bead winding machines. Verify all Tire Builder Process Control System checks are being made, documented, and reacted to when out of spec. Refer to QAI 2522. Question operators, review equipment set-up/measurement documentation, compare run card to equipment settings.

documented?

Area

SubArea

Ques#

Question

Truck
Tire Bldg Tire Bldg 65 Are routine audits being performed in Tire Building area? BREAKER BAND BUILDING:

8.1.10 Is traceability system in place?

TIRE BUILDING PROCESS

8.3.5 8.3.9 Is there a process to check machine set-up and components at beginning of shift and after every code change? Is there a system to identify and segregate nonconforming materials and components?

8.3.12 Is component traceability effective? 8.3.13 Is spotting specified? 8.3.14 Is spotting followed? 8.3.19 Is there a process to measure and control critical process parameters? 8.3.24 Are FIFO procedures observed? 8.3.28 Is the necessary EQ in good working condition and properly stored?

GENERAL
Transferir p/ OBT Transferir p/ OBT 8.4.1 8.4.2 Are visual aids showing misplaced component effect on cured tire displayed in the tire building area? Is there effective communication such as video showing impact of cause & effect of yield issues (performance issues)

Tire Bldg

Brkr Band Bldg

66

Are the correct quality requirements available to the operator? Are requirements for machine set-up correctly identified? Have age limits been established? Are age limits followed? Does segregation for off-spec bands exist?

67
68

69
70

Tire Bldg

Bldg Inst

71
72

Are the correct quality requirements available to the operator? Are requirements for machine set-up correctly identified? Are latest set-up and running cards available to the operator? Is there a component traceability system? Is the tire room directly notified in case of repeating defects and are actions taken? Are green tires/carcasses stored to prevent damage and distortion? Are age limits followed for green tires/carcasses? Are scrap carcasses / green tires properly segregated? Is there a system to follow code changes to insure tire codes are started up correctly?

73
74

75
76

77
78

79
Tire Bldg General 80

Is there evidence that specifications and run cards are being followed by associates?

GUIDELINES

Is there documentation to verify these audits are performed on a regular basis?

All produced components must be stored with tags showing dates and product codes. Tags to be registered and filed for easy traceability.

Review documentation, must include basic machine settings, component checks to dimensional requirements and age limits. Documentation may include operator check sheets, signatures on material tags, computer sign-on, etc.) All off spec material must be identified and segregated. There must be baskets/bins for each component cut off - must be clearly identified. No material left on tire machine railing/floor. Non compatible material must be clearly identified. Green component tags must be recorded and filed in relation to the green tire for easy later retraceability? The specified splice spotting for the tire code running on the building machine should be posted at easy access for the builder. At each code change, the correct spotting must be checked. At machine set up, the splice spotting is checked. If for uniformity/downstream reasons the spotting is changed, the specification must be revised and posted at the machine. Documented measurements for critical parameters, as defined in plant control plan, should be available for review. If any measurements are out of tolerance, corrective action should be noted. First In First Out procedures must be observed for all components and green carcasses tires. Components being used/stored at the machine from the same production run/date will be considered to be in compliance. All EQ equipment must be properly stored and kept in good working condition.

Observe signage or placards in tire building area. Record of training for those who can impact - component prep, tire builders, etc.

Has the operator been correctly instructed and are the quality requirements for his function clearly defined and available to him. Each tire code has to have an up-dated and complete set-up card. This card has to be available at the machine and understood by the operator when the tire code is up. Age limits should be included in the local working specs and should be known to the operators and service people handling green tire components. Records on actual vs spec for age limits should be available on the individual material tags. Off-spec bands should be clearly identified and immediately segregated from the good ones. They must be stored with clear identification on separate racks.

Has the operator been correctly instructed and are the quality requirements for his function clearly defined and available to him. Each tire code has to have an up-dated and complete set-up card. This card has to be available to the machine and understood by the operator when the tire code is up. Latest revisions of set-up and running cards should be available at the building station. The cards relevant to the running code should be posted for easy access by the builder at the machine. All components should be properly tagged indications. Material code-dimensions-production date, the final green tire should be marked with builder sticker. In case of repeating defects occurring, the tire classifier or his representative should immediately inform the affected department. Records of these occurrences should be kept together with the corrective actions and subsequent results. Green tire / carcasses should be stored / transported in trucks / conveyors free of damage to prevent tire damages or excessive deformation or contamination. System to define number of tires/carrier. Age limits as specified by plant specification should be respected. All scrap carcasses / green tires should be stored separately from the regular ones at a specific location / truck to avoid further usage in the manufacturing process. A written procedure for tire code changes should exist. All operators / service personnel / supervisors should be properly trained in this matter. A copy of the procedure should be available at the machine for reference.

Question operators, review equipment set-up/measurement documentation, compare run card to equipment settings.

Area

SubArea

Ques#

Question

Rear Farm & OTR

TT/OTR Laminadora 7.13.1 7.13.2 7.13.3 7.13.4 7.13.5 7.13.6 7.13.7 Tire Bldg Tire Bldg

STRIP LAMINATOR
Is the correct compound being used and is there a compound traceability system for the strip laminator? Are the drum and the program correct to produce the tire? Is the tire weight being monitored according to the established frequency and is within tolerance? Are the tires correctly painted and identified? Are all the quality information required available to the operator? Is the TCU in good working condition and controlling to the specified temperature? Is there maintenance planned for the strip laminator and is being done?
Are routine audits being performed in Tire Building area? BREAKER BAND BUILDING:

65

8.1.10 Is traceability system in place?

TIRE BUILDING PROCESS

Is there a process to check machine set-up and components at beginning of shift and after every code change?

8.3.5

8.3.9

Is there a system to identify and segregate nonconforming materials and components?

8.3.12 Is component traceability effective? 8.3.13 Is spotting specified? 8.3.14 Is spotting followed? 8.3.19 Is there a process to measure and control critical process parameters? 8.3.24 Are FIFO procedures observed? 8.3.28 Is the necessary EQ in good working condition and properly stored?

GENERAL
Transferir p/ OBT Transferir p/ OBT 8.4.1 8.4.2 Are visual aids showing misplaced component effect on cured tire displayed in the tire building area? Is there effective communication such as video showing impact of cause & effect of yield issues (performance issues)

Tire Bldg

Brkr Band Bldg

66

Are the correct quality requirements available to the operator? Are requirements for machine set-up correctly identified? Have age limits been established? Are age limits followed? Does segregation for off-spec bands exist? Are the correct quality requirements available to the operator? Are requirements for machine set-up correctly identified? Are latest set-up and running cards available to the operator? Is there a component traceability system? Is the tire room directly notified in case of repeating defects and are actions taken? Are green tires/carcasses stored to prevent damage and distortion? Are age limits followed for green tires/carcasses? Are scrap carcasses / green tires properly segregated? Is there a system to follow code changes to insure tire codes are started up correctly?

67
68

69
70 Tire Bldg

Bldg Inst

71
72

73
74

75
76

77
78

79
Tire Bldg General 80

Is there evidence that specifications and run cards are being followed by associates?

GUIDELINES

Is correct identification on the tags and date of manufacture ? Are all batched-off compounds properly approved and identified? Is the traceability system effective? Review if the drum and the CLP program are the specified to the tire being produced. Is correct weighing scale in use? Is scale calibrated at specified frequency? Is tire weight checked at specified frequency? Are weights taken documented? Are the tires segregated and corrective actions implemented when the weight is out of spec.? The painting should be according to the specification. The tire should be identified with type, date and hour. All tires from a car should be identified. Each car should have only one type of tire. Review if the last set up specification revision is available. Is the cooling temperature specified in the running card? Is there any leak on the TCU? Are actual temperatures following the spec at all zones? Is the frequency established, documented and being followed? Are the records of check lists available? Is there evidence of corrective actions taken in response to nonconformist items?
Is there documentation to verify these audits are performed on a regular basis?

All produced components must be stored with tags showing dates and product codes. Tags to be registered and filed for easy traceability.

Review documentation, must include basic machine settings, component checks to dimensional requirements and age limits. Documentation may include operator check sheets, signatures on material tags, computer sign-on, etc.)

All off spec material must be identified and segregated. There must be baskets/bins for each component cut off - must be clearly identified. No material left on tire machine railing/floor. Non compatible material must be clearly identified. Green component tags must be recorded and filed in relation to the green tire for easy later retraceability? The specified splice spotting for the tire code running on the building machine should be posted at easy access for the builder. At each code change, the correct spotting must be checked. At machine set up, the splice spotting is checked. If for uniformity/downstream reasons the spotting is changed, the specification must be revised and posted at the machine. Documented measurements for critical parameters, as defined in plant control plan, should be available for review. If any measurements are out of tolerance, corrective action should be noted. First In First Out procedures must be observed for all components and green carcasses tires. Components being used/stored at the machine from the same production run/date will be considered to be in compliance. All EQ equipment must be properly stored and kept in good working condition.

Observe signage or placards in tire building area. Record of training for those who can impact - component prep, tire builders, etc.

Has the operator been correctly instructed and are the quality requirements for his function clearly defined and available to him. Each tire code has to have an up-dated and complete set-up card. This card has to be available at the machine and understood by the operator when the tire code is up. Age limits should be included in the local working specs and should be known to the operators and service people handling green tire components. Records on actual vs spec for age limits should be available on the individual material tags. Off-spec bands should be clearly identified and immediately segregated from the good ones. They must be stored with clear identification on separate racks. Has the operator been correctly instructed and are the quality requirements for his function clearly defined and available to him. Each tire code has to have an up-dated and complete set-up card. This card has to be available to the machine and understood by the operator when the tire code is up. Latest revisions of set-up and running cards should be available at the building station. The cards relevant to the running code should be posted for easy access by the builder at the machine. All components should be properly tagged indications. Material code-dimensions-production date, the final green tire should be marked with builder sticker. In case of repeating defects occurring, the tire classifier or his representative should immediately inform the affected department. Records of these occurrences should be kept together with the corrective actions and subsequent results. Green tire / carcasses should be stored / transported in trucks / conveyors free of damage to prevent tire damages or excessive deformation or contamination. System to define number of tires/carrier. Age limits as specified by plant specification should be respected. All scrap carcasses / green tires should be stored separately from the regular ones at a specific location / truck to avoid further usage in the manufacturing process. A written procedure for tire code changes should exist. All operators / service personnel / supervisors should be properly trained in this matter. A copy of the procedure should be available at the machine for reference.

Question operators, review equipment set-up/measurement documentation, compare run card to equipment settings.

Area

SubArea

Ques#

Question

GUIDELINES

Curing & Final Finish

Curing Process Curing

N
Is there documentation to verify these audits are performed on a regular basis?

81

Are routine audits being performed in the curing area?

General
9.1.4 9.1.5 9.1.8 9.1.10 Is spotting specified? (Radial) Is spotting being followed? (Radial) Is bladder pull policy established and being followed? Is EQ identified, in good working condition and properly stored? Spotting should be specified for all consumer and MRT tires. Other tire lines are N/A. Confirm spotting is being followed. Is there a defined bladder pull policy that includes analysis of failed bladders for all codes? Confirm that the bladder pull policy is being followed. Updated EQ equipment inventories must be maintained. Mold rings must be stored to prevent damage.Verify plant system for inspection/condition of PCI rings. Molds must be stored indoors per the guidelines listed in GQMTS: P16C2. Is there a set-up sheet? Verify press setting meet the parameters of press spec. Is the shaping pressure verified for all presses at each mold change. If plant uses EOT computer to measure shaping, then shaping graph does not need to be placed on each press (one measurement every 2 seconds). A record of the tracing (or digital photo), for all molds, must be available on request A record of incoming mold stamping verification, to the Stamping Drawing, as well as Qtech verification that the mold stamping conforms to the Corporate Design Specification must be available. Compare plant mold stamping systems to QAI 2303 (flow chart, RACI chart, etc) A record that Mold Set-up Cards, and 1st & Last Tire Check Sheets conform to the Mold Stamping Drawing and Corporate Design Specification must be available. Verify that the system insures required mold work is performed before mold goes back in service. Records must be maintained and actions taken for mold conditions out of tolerance. Last tire check sheet must include signature of responsible associate. A verification of the tire tracing versus the 1st Tire Check Sheet will be made and documented by a second Qtech associate (or appropriate authorized associate), to verify the stamping details are correct. This should be made by the following shift, but must be made within 24 hours. Is there a written mold cleaning system considering frequency according mold type? Is there a system to verify there is no mold damage or missing slugs after mold cleaning in the press? Is this system being followed? Is the cleaning media used by the plant authorized? Tires must be sampled and graded according QMS_QAI_IAT_2500 and action plans should be established for any item graded 2 or 3. Records must be maintained and specifications for grading (including photographs) must be available. Review plant mold repair program. Are project cure audits documented. Does plant have a plant cure committee? There must be a documented action plan with assigned responsibility with completion dates. If no non conformances this question is N/A Are the thermocouples run according GQMTS: P16Q8, all Levels 1-4? Confirm that the thermocouple results meet the

9.1.11* Are shaping pressures correctly defined and monitored? 9.1.15 Do all molds have a tracing or digital photo on file?

Do all incoming molds, (new, repair, plant transfer), have correct 9.1.16* stamping?

9.1.17* Are Mold Set-up Cards and 1st & Last Tire Check Sheets correct?

9.1.19* Is there e a second Qtech verification that the 1st Tire Check is correct?

9.1.21 Does the plant have and adhere to a mold cleaning cycle system? 9.1.23 Are appropriate corrective actions taken in response to world class appearance standards (mold appearance and flash)? 9.1.35 Are project cure audit results documented?

Are appropriate corrective actions for project cure audit findings taken 9.1.36 and documented? 9.1.37* 9.1.38 * 9.1.39 9.1.40* 9.1.41* 9.1.42 Are thermocouples run per requirements of appropriate project cure level? Are thermocouple records available? Was the initial curing time correctly established? Is there an established C-Clamp monitoring system in place? Do C-Clamp sampling frequencies meet the cure level requirements? Are C-Clamp R&R study available?

cure specs for each tire line and cure level.

Verify records. Check if thermocouple test have been on all press types. Was every new press released based on thermocouple results. The cure time must be established based on existing mold match or a thermocouple test. (Reference GQMTS P16Q08

and P16Q13). If a mold match is used, there must be evidence of a thermocouple study performed on the tire used
Plant must have assigned responsibility for the function to an associate (according to GQMTS P16Q13). For any cure level, Cclamp gauge monitoring is the only acceptable gauge monitoring system. Actual sampling frequency must meet or exceed GQTMS16Q03. Study must be made according to the instructions in QAI 2506. Review the results by operator. Review Cure Adjustment Report Summary as noted in QAI 2506, par 15.0. Review plant warm-up procedure for cold mold, hot mold and after CO2 cleaning as per GQMTS 16H2.

Are corrections made to cure times initiated from statistical analysis of 9.1.43 C-Clamp results? 9.1.44 Curing Process Curing Genl 82 Is there a plant mold warm-up procedure defined?

Are Green Tire limits specified?

83 84 85 86

Are age limits followed? Is there a system in place to reduce/eliminate the possibility of loading the wrong green tire in a press? Are the correct quality requirements available to the concerned operators/ monitors? Are requirements for machine set-up correctly identified?

Verify that there is a system in place to track the age of the green tires. Confirm green tire inventory is within the age limits. Are there documented procedures/training records for press operators? Are the last revision of curing specs posted on each press? Is the shaping recorded posted on each press? Are the curing graphs for services and tolerances posted on each press? Verify press settings meet the parameters specified by the spec. Are the set-up sheet posted on each press including PCI?

87 Is there a first tire system in place? Is there evidence that specifications and run cards are being followed by associates? Are automatic or manual alarms for temperature/pressure in place for presses, pot heaters and services? Are the cures being extended for low green tire temperature? Are requirements for machine set-up correctly identified? Have green tire age limits been established? Are age limits followed? Are routine audits being performed in the Final Finish area? Are repair materials properly identified?

A system must be in place to check first tire after each mold change, cure change or coverplate, panel or stencil change. First tire sheet must be placed in a visible position on each press and signed by the responsible associate. No press should be running without a First Tire Check Sheet. Question operators, review equipment set-up/measurement documentation, compare run card to equipment settings. Verify alarms are in place and in working condition? Are the alarm upper and lower limits set to the specifications? Are the reaction to the different alarm defined and known by the associates concerned? Is the impact of every alarm type on safety and quality known? Is there a written procedure/spec/running card defining cure extended presses due low green tire temperature? What is the procedure to measure green tire temperature? Is there a set-up sheet? Green to cure limits must be specified. Verify system that identifies age of green tires. Identify system for controlling green tire age. Confirm green tire inventory is within age limits. Is there documentation to verify these audits are performed on a regular basis? Compound and cements must have material identification and age limits. Review procedure (1X3) and data. Review documented procedure.

88 89 91 Curing Process OTR Inserter Oper 92 93 94 FinlFinish General 95 10.1.7

Is there a check tire procedure to check dynamic balance machine 10.1.27* accuracy? 10.1.35* Is there a tire weight system in place?

10.1.42* Are correct limits being utilized for commercial tires being checked for LRO/RRO/balance, and is the system being audited? FinlFinish Prod Test&Feedbac k 96

Pull a copy of the plant's grading chain and compare to the appropriate section of the GQMTS-Consumer. Review plant audit records to verify limit tables are being audited for each machine monthly, and a minimum of 25% of SKU's checked monthly.

Is there an inspection / classification system to insure compliance to specification?

Review documented procedures for Cured Tire Inspection / FV / Balance / Grinding.

97 Are standards complete, up to date and understood by associates? 98 99 Is there a feedback system effective and appropriate to production for defects found? Are nonconforming tires properly identified and segregated? Is there a documented system to assure that the correct tires are shipped to and have the proper customer markings (I.e., force marks, balance marks, customer specific labels, etc). Is there a system to assure that ground tires meet appearance, uniformity and balance standards? Are daily quick checks done on static balance equipment? Is there a system to audit outgoing quality? Is there evidence that specifications and run cards are being followed by associates? Are the correct limits being utilized for tires being forced? Are the correct limits being utilized for tires being balanced? While interviewing inspectors and operators in FF area, note whether standards are available, current and understood. Look for immediate effective feedback systems for defect found to plant associates & management. Review plant procedure for segregating tires ( Visual inspection / FV / Balance / Weight / X-ray and any Non Conformity tire). Look for a non conforming area to contain tires. Records must indicate compliance. System being utilized must be described. System must be in place that verifies product meets all customer labeling requirements and insures correct product is being shipped. Review process flow on floor for ground tires as to their inspection for appearance, uniformity and balance. Review procedure data. Do the audit teams audit results verify the presence of an outgoing quality audit system? Question operators, review equipment set-up/measurement documentation, compare run card to equipment settings. Pull a copy of the plant's grading chain and compare to the appropriate specification. Pull a copy of the plant's grading chain and compare to the appropriate specification.

100 101 103 104 105 106 107

Area

SubArea

Ques#

Question

Warehouse& Shipping

FinlFinish

Whse/Ship

108

Are Warehouse & Shipping adequate to ensure a quality product reaches the customer?

109 = 100

Is there a documented system to assure that the correct tires are shipped to and have the proper customer markings (i.e., force marks, balance marks, customer specific labeled, etc)? Is there a system to trace and analyze customer returns? Are corrective actions for returned tires being taken? Is there a system to respond and document customer complaints in a timely manner? Are 8D (or similar) customer follow-up reports supplied by Corporate office? Is there evidence of a plan to comply with 8D (or similar) corrective actions? Are repairs performed per established specifications/procedures?

110 111 112 113 114 115

GUIDELINES

Handling should not have potential to damage tires, should have proper labeling, should be no mixed loads, etc. Audit a trailer that is being loaded to look for cleanliness, integrity of trailer roof and absence of hazards.

Records must indicate compliance. System being utilized must be described. System must be in place that verifies product meets all customer labeling requirements and insures correct product is being shipped.

Review documented procedure - must cover OE and renewal. Review records. Evaluate length of loop to respond to complaints compared to customer requirements and their internal requirements. Is there a system in place to review/file customer issues which have been distributed through the Corporate office? Can the plant demonstrate a place to comply with the intent of the document? Review written procedures - question operators

Area

SubArea

Ques#

Question

Monitoring & Lab. Testing

Tire Monitor& Lab Testing General 116 Are routine audits being performed at theTire monitoring/Lab areas? The objective of this audits is to ensure compliance to all applicable government, corporate and customer requirements

11.0.2* Is there documented evidence of corrective action on nonconformance items? 11.1.1 Is the Cut Tire testing done at the specified frequency? (GQMTS S04C)? 11.1.2 Are production release and tire monitoring cut tire programs in alignment with GQMTS: S04C? 11.1.4 Are corrective actions for cut tire variations implemented and documented? 11.1.6 Is Lab Testing equipment in good working condition and stored correctly? 11.1.20 Is there evidence that specifications and run cards of the tires currently being tested are being followed by associates? Tire Monitor& Lab Testing Tire Monitor&Lab Testing

117 Are procedures available for selecting test sets? 118 Are tire sets correctly identified? 119 Are tests performed at the required frequency? 120

Is tire testing performed for compliance to legal and customer standards?

121 Are test sets conditioned as required prior to starting any tests? 122 Are test conditions documented? 123 Are records kept as per established procedures? 124 Are back-up tests run as required?

GUIDELINES

Is there documentation to verify these audits are performed on a regular basis? There must be a documented action plan with assigned responsibility with completion dates. If no non conformances this question is N/A. Review records and compare to requirements of S04C. Review records for alignment to GQMTS requirements. Review records for cut tire sample that did not meet spec and look for reaction. The Lab testing equipment must be in good working condition to guarantee the correct test result. Is there a documented PM program. Look for oil leaks, rust on bearing surfaces, rim damage, etc. Question operators, review equipment set-up/measurement documentation, compare run card to equipment settings.

Check documentation

Tire sets in lab or lab storage area must have a tag or marking tying them to the test records.

Review records for frequency compliance.

Review records.

Review records.

Review reports, must include required information.

Review records for all Legal / Monitoring testing samples that did not meet spec and look for reaction.

Area

SubArea

Ques#

Question

Engineering Requirements & Calibration

Mixing/Qual & Labs Mixing/Qual & Labs 6.3.1 Are BB and pigment room scales calibration procedures being followed and documented? Are all banbury lubrication systems using correct distribution blocks and lube oil rates for each banbury? Are all banbury process oil systems using correct distribution blocks and process oil rates for each banbury? Are all yoke and hydraulic oil pressures set-up correctly for each banbury? Have banbury inspections been done to the required frequency? Are measuring devices properly calibrated and documented accordingly?

6.3.4
6.3.5 6.3.6 6.3.7 6.3.X Stock Prep Stock Prep

Are extruder clearance checks done on a regular frequency, completed 7.10.1 and documented? Are calender roll contour checks done on a regular frequency, 7.10.2 completed and documented? 7.10.3 Have belt speeds been synchronized as appropriate?

Tire Bldg

Tire Bldg 8.2.2 Are calibration records available and up-to-date?

8.2.3 8.3.20

Are calibrated instruments identified correctly?

Are control sheets with specified tolerances for each drum type available in the drum booth? Are repair and maintenance records per drum part number available 8.3.21 and up to date? 8.3.22 Are drums certified prior to leaving the drum booth?

Curing

Curing

9.1.9 Are all presses (that require bladder leak detectors) equipped with bladder leak detectors? 9.1.24 Are press alignment procedures and frequency established? 9.1.25 Are press alignments completed as per procedure and frequency?

9.1.26

Are loaders aligned correctly to a specified frequency? (minimum every mold change)

9.1.27 Is laser loader alignment equipment being used?

9.1.28 Are green tires holders/pans aligned correctly with every mold change? 9.1.46 Are air vents and steam traps on steam header functional? 9.1.50* Is there a list of critical instruments which require calibration?

9.1.51* Are calibration records available and up-to-date and correct tolerance used? 9.1.52 Are calibrated instruments identified correctly?. 9.1.53 Is the PCI system in good working condition? Are automatic cure extension timers in place and operational? 90 Final Finishing Final Finishing 10.1.6 Are repair presses and heaters calibrated? Are dynamic balance calibrations conducted as required with 10.1.32 documented results available?

Tire Monitor& Lab Testing

Tire Monitor& Lab Testing

11.1.7*

Is there a list of critical instruments which require calibration? 11.1.8* Are calibration records available and up-to-date? 11.1.9* Are calibrated instruments identified correctly?.

GUIDELINES

The calibration of all scales must also be current (quarterly). Verify calibration at Instrument Lab. Each size banbury has Goodyear specifications for correct lube oil distribution blocks and correct lube oil flow rates based on RPM's. This information can be found in Engineering Knowledge Database listed under Mixing /0004 How To...(Equipment)/Reductions in Dust Ring Oil and Waste. Each size banbury has Goodyear specifications for correct process oil distribution blocks and correct process oil flow rates based on RPM's. This information can be found in Engineering Knowledge Database -Mixing /0004 How To...(Equipment)/Reductions in dust ring oil and waste. Each size banbury has Goodyear specifications for correct yoke pressure. This information can be found in Engineering Knowledge Database - Mixing/0004 How To.(Equipment)/Reductions in Dust Ring Oil and Waste. Are the inspection reports available and was the required frequency respected?

For other lab equipment than Rheometer, like load cells, timers and thermocouples should be calibrated by instrument tech. Verify calibration frequency and records.
Is the schedule available? Is it being followed? Is the check being performed? Is the result documented? Is the corrective action being taken and documented? Is the schedule available? Is it being followed? Is the check being performed? Is the result documented? Is the corrective action being taken and documented? Is the schedule available? Is it being followed? Is the belt speed synchronization being performed? Is the result documented? Is the corrective action being taken and documented? Accurate up-to-date calibration records of all critical instruments must be available. The records must show the actual calibration dates and results as well as the name of the checker. Eventual adjustments, repairs or replacements must be recorded. The instruments requiring calibration should be tagged with the instrument identification number, as well as next required date for calibration. Alternated ID placement optional (inlet line, door panel, etc) for situations not conducive to placing the sticker on the instrument/gauge. Control sheets must exist in the drum booth for each giving the nominal value and tolerances for each drum type. Any repair on a drum must be recorded in the individual drum log books. Each drum leaving the drum booth must be checked and certified for the settings specified on the set up card. Bladder leak detectors currently available work in Standing post and Bag in Well presses running steam-gas cures. Additional bladder detectors and press combinations are being evaluated. As they are approved, they will be added to the requirement. Not

included in the scope of the question are Dome, electric, pot heater and steam-water cure cycle presses, and presses with manual unloading and tire inspection by press operator.
Is there a documented press alignment verification program in place and are the established frequencies respected. For EMEA, procedures and frequencies specified in GQMTS:

P16F1. For the remaining Regions, the plant should specify guidelines and frequency, with frequency not to exceed three years.
Press alignment check sheets should be available Confirm frequency of alignments are being met. Is there a written procedure that includes frequency? Do records confirm the system is being followed? Are corrective actions documented for out-of-tolerance conditions? (For manual loaded presses: Respond N/A) The plant must be using the Americana laser alignment procedure (preferred method) or equivalent laser/non-laser alignment system. Any equivalent non-laser system must be evolved than the traditional plum-bob system. (For manual loaded presses: Respond N/A)

Is there a written procedure that includes frequency? Do records confirms the system is being followed? (Enter N/A for green tire loading trucks and robotic systems.) Review header data Certify that air vents and steam traps are operational All critical setting tools should be identified. A list should be available with an indication of the type and frequency of calibration checks. Accurate up-to-date calibration records of all critical instruments should be available at Calibration Lab. The records should show the actual calibration dates and results as well as the name of the checker. Eventual adjustments, repairs or replacements should be recorded. Tolerance must be in line with GQMTS 16J1, review the plant procedure. Reference standards must be traceable to national standards and up to date. The instruments requiring calibration should be tagged with the instrument identification number, as well as next required date for calibration. Is the PCI system in good working condition? Are the correct pressure and alignment set-up correctly? Manually check that automatic cure extenders work on one press. Review plant procedures for calibration and review documentation. Review procedure and results.

All critical machine setting tools (Pressure gauges, setting gauges,) should be identified. A listing should be available at the Lab Testing (based upon QMS_ADM_CAL_0001 for North America plants or those plants referencing Goodyear's QMS System - QEHSPM Quality, Environment, Health & Safety Policy Manual for the Design and Manufacture of Tires). For those International plants that do not reference Goodyear's Global QMS system, local documentation should identify critical instruments requiring calibration. Required frequency of calibration checks should be part of the documentation.on checks. Accurate up-to-date calibration records of all critical instruments should be available at the Calibration Lab. The records should show the actual calibration dates and results as well as the name of the checker. Eventual adjustments, repairs or replacements should be recorded. The instruments requiring calibration should be tagged with the instrument identification number, as well as next required date for calibration.

Area

SubArea

Ques#

Question

External PPQ Audit

13.07 Is there evidence of corrective action taken when cured defect trends are identified in the plant?

13.10 Are all new defective returns being analyzed?

13.11* Is there a system to audit outgoing appearance quality?

13.12 Are all tires (from the PPQ Audit of Outgoing Quality reinspection) free of "functional" irregularities?

13.13 Are all tires (from the PPQ Audit of Outgoing Quality reinspection) within specified uniformity and balance limits?

13.14 Is the WCA average (from the PPQ Audit of Outgoing Quality reinspection) equal to or better than 1.25?

13.15 Is there evidence (inspector stamp/sticker) of a finished tire inspection process?

13.16 Is there a system to follow up with inspectors when irregular tires are observed as part of the plant's regular self audit of outgoing quality?

13.18 Are corrective actions in response to tire weight variations implemented and documented?

13.23 Is there a system in place to verify shipment accuracy?

13.24* Is there a documented system to contain suspect tires within the plant or warehouse?

13.25* Is the tire containment system effective?

13.26 Is there an active customer / dealer visit program? Are returned tires put on display and communicated to manufacturing 13.28 associates? Do all associates know the defectives that cause adjustment? Are corrective actions taken?

GUIDELINES

For repeating defectives are there records that indicate corrective actions have taken place? Are there documented "trigger" points when corrective actions are made?

Are new defective ( excluding uniformity) from local market being returned to the Plant? In others market, are you tracking by adjustments data or special return for analysis? Refer to QAI-2500

and QMS_ADM_IAT_0001. Do the audit teams' audit results verify the presence of an outgoing quality audit system?

If one or more tires have "functional" irregularities, answer NO. - If a tire exceeds any force parameter, repeat 3 times and obtain an average reading. The average must be within 2 lbs of the limit for RFV, R1H and LFV and within 3 lbs of the limit for conicity. For RRO/LRO, undulation (bulge & valley), average must be within 10% of the limit. - Dynamic balance cannot exceed the limit by more than .5 ozs. If any tire exceeds these requirements, the answer is NO.

Overall average of tires checked during WCA rating must be equal to or below 1.25 to answer YES.

Do all tires have inspector stamps/stickers? For plants with bar codes and computerized inspection records in Final Finish, application of inspector stamps is optional (per Regional QTECH's direction, but computer records must be able to identify when and who inspected the tire. Any code selected as part of the OQL inspection that is not 100% compliant (with stamps or computer bar code traceability) will be considered to have never been inspected and will be held for reinspection by the plant.

Review records of outgoing quality inspection results- is there evidence of documented follow up when any irregular tires are observed?

Review records for tire weight sample that did not meet spec( greater than spec plus 0.5% and less than spec minus 1.5%) and look for reaction. Compare results of PPQ Global Audit OQL tire weight to monthly plant tire weight Quality Indicator.

Review shipping records. Look for signoff on the quantity.

Look for evidence of documented tire containment system.

Look for evidence that suspect tires remain within Goodyear control and are not shipped

Look for evidence of customer / dealer communications and visitation documentation. Customer/dealer visits must include plant personnel (Qtech, Manufacturing, hourly associates, etc.)

Look for evidence of returned tire displays / communication with manufacturing associates. Interview associates to confirm if they are aware about the main causes of adjustment. Look for evidences of actions taken to solve adjustment causes.

Plant : OUTGOING QUALITY AUDIT Date

TIRE SIZE/Type: Serial Number:

Factory Code:
INSPECTOR STAMP Barcode Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required) X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required) MOLD PN GRADE

Usage/Customer:
APPEARANCE RATING (WORLD CLASS STANDARDS) Actual Weight RFV RF1H LF Con RRO LRO Undulation TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x !! The cells for the Spec values above MUST contain either a spec value OR an "x" . !! x x

TIRE SIZE/Type:

Serial Number:

Factory Code:
INSPECTOR STAMP Barcode Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required) X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required) MOLD PN GRADE

Usage/Customer:
APPEARANCE RATING (WORLD CLASS STANDARDS) Actual Weight RFV RF1H LF Con RRO LRO Undulation TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x !! The cells for the Spec values above MUST contain either a spec value OR an "x" . !! x x

TIRE SIZE/Type:

Serial Number:

Factory Code:
INSPECTOR STAMP Barcode Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required) X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required) MOLD PN GRADE

Usage/Customer:
APPEARANCE RATING (WORLD CLASS STANDARDS) Actual Weight RFV RF1H LF Con RRO LRO Undulation TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x !! The cells for the Spec values above MUST contain either a spec value OR an "x" . !! x x

TIRE SIZE/Type:

Serial Number:

Factory Code:
INSPECTOR STAMP Barcode Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required) X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required) MOLD PN GRADE

Usage/Customer:
APPEARANCE RATING (WORLD CLASS STANDARDS) Actual Weight RFV RF1H LF Con RRO LRO Undulation TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x !! The cells for the Spec values above MUST contain either a spec value OR an "x" . !! x x

TIRE SIZE/Type:

Serial Number:

Factory Code:
INSPECTOR STAMP Barcode Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required) X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required) MOLD PN GRADE

Usage/Customer:
APPEARANCE RATING (WORLD CLASS STANDARDS) Actual Weight RFV RF1H LF Con RRO LRO Undulation TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x !! The cells for the Spec values above MUST contain either a spec value OR an "x" . !! x x

TIRE SIZE/Type:

Serial Number:

Factory Code:

Usage/Customer:

INSPECTOR STAMP Barcode

Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required)

X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required)

MOLD PN

GRADE

APPEARANCE RATING (WORLD CLASS STANDARDS)

Actual Weight

RF1H

LF

Con

RRO

LRO

Undulation

TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x !! The cells for the Spec values above MUST contain either a spec value OR an "x" . !! x x

TIRE SIZE/Type:

Serial Number:

Factory Code:
INSPECTOR STAMP Barcode Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required) X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required) MOLD PN GRADE

Usage/Customer:
APPEARANCE RATING (WORLD CLASS STANDARDS) Actual Weight RFV RF1H LF Con RRO LRO Undulation TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x !! The cells for the Spec values above MUST contain either a spec value OR an "x" . !! x x

TIRE SIZE/Type:

Serial Number:

Factory Code:
INSPECTOR STAMP Barcode Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required) X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required) MOLD PN GRADE

Usage/Customer:
APPEARANCE RATING (WORLD CLASS STANDARDS) Actual Weight RFV RF1H LF Con RRO LRO Undulation TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x x x

!! The cells for the Spec values above MUST contain either a spec value OR an "x" . !!

TIRE SIZE/Type:

Serial Number:

Factory Code:
INSPECTOR STAMP Barcode Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required) X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required) MOLD PN GRADE

Usage/Customer:
APPEARANCE RATING (WORLD CLASS STANDARDS) Actual Weight RFV RF1H LF Con RRO LRO Undulation TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x !! The cells for the Spec values above MUST contain either a spec value OR an "x" . !! x x

TIRE SIZE/Type:

Serial Number:

Factory Code:
INSPECTOR STAMP Barcode Force Mark Balance Mark (Y or N) (Y or N) (Leave blank if not (Leave blank if not checked or not checked or not required) required) X-Ray Stamp MRT Only (Y or N) (Leave blank if not checked or not required) MOLD PN GRADE

Usage/Customer:
APPEARANCE RATING (WORLD CLASS STANDARDS) Actual Weight RFV RF1H LF Con RRO LRO Undulation TOTAL DYNAMIC BAL.

COMMENTS: Spec Specs ===> x x x x x x x !! The cells for the Spec values above MUST contain either a spec value OR an "x" . !! x x

Static Balance (MRT only)

Static Balance (MRT only)

Static Balance (MRT only)

Static Balance (MRT only)

Static Balance (MRT only)

Static Balance (MRT only)

Static Balance (MRT only)

Static Balance (MRT only)

Static Balance (MRT only)

Static Balance (MRT only)

Uniformity Summary (Including Tire Weights)

Tire Weight Summary

Within Spec +0.5% and Spec -1.5%

# # over spec Measured RFV RF1H LF Con RRO LRO Undulation Total Dyn Bal Static Bal
(MRT Only)

0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0

% Total Uniformity Measurements within specs # Tires

Greater than Less than Spec Spec +.5% 1.5% 0 0

0.0% Force Marking #

0.0%

0.0%

TOTAL

Yes No

0 0

#DIV/0! #DIV/0!

Appearance Summary Grades # % 0 #VALUE! #VALUE! 1 #VALUE! #VALUE! 2 #VALUE! #VALUE! 3 #VALUE! #VALUE! Average ==> #VALUE! Tire Appearance - Tires Graded >1 Reason Graded 2 Graded 3

Yes No

Balance Marking # % 0 #DIV/0! 0 #DIV/0!

Inspector Stamps # % OK 0 #DIV/0! Illegible 0 #DIV/0! Missing 0 #DIV/0! X-Ray Marking (MRT only) # % Yes 0 No 0