6v0,

04Jul2013
Contract Manufacturer
Site Name:
Site Address:
Website:
Site Contact Name:
Site Contact Phone #:
Site Contact Fax #:
Site Contact e-mail:
Survey Date:
Commscope Evaluator Name:
Commscope Evaluator Phone:
Section Description Weight
1.0 General 12
2.0 Quality 24
2.1 10
3.0 Materials
3.1 Unplated Components 4
3.2 Raw Material 4
4.0 Design and Engineering 4
5.0 4
6.0 Process
6.1 Plating Process 30
6.2 Post Plating Operations 4
7.0 Environmental 4
100
Assess
ment
0
Good 3,
Acceptable
2, Poor - 1
001.402.691.3788 O; 001.402.541.8993 M
CommScope Finishing Assessment Checklist
This list is intended to be used as an assessment tool for Commscope Product Engineering to perform
evaluations of supplier capability and capacity.
If a supplier has more than one location, a separate technical assessment should be provided for each
location.
"New Product Introduction" and
"Product or Process Changes"
Terry Kamino
Table of Assessment Subjects
Tooling (consider racks and barrels as
tooling) and Preventative Maintenance
Total
Score
Question Answer
Total Score (100 is the maximum)
1
2
Company size, by annual sales? Ownership (public
/ private)?
0
3
Current or former supplier of CommScope /
Andrew? Provide any details of significance
(products, amount of business in dollars, production
period (dates), etc).
0
4 Type of certification(s)? (ISO, TL, etc) 0
5
Number of facilities other than this location? The
year this facility was started? The year the company
was started?
0
6 Personnel Headcount: --- --- ---
7
Engineering:
Design, Process, Quality, Other
0
8
Quality Personnel (non-engineering): Manager,
inspectors, process checkers, etc
0
9 Maintenance Personnel 0
10 Production (Direct) Workers 0
11 Waste Treatment Personnel
12 Total Headcount in the facility 0
13
Provide an organization chart.
0
14
Contact information: Identify persons for process
engineering, quality engineering, customer service.
Provide contact information.
0
15
Provide an equipment-process capabilities matrix if
available. If not, complete TAB "Process Matrix".
0
16
Provide a list of specifications and tests if available.
If not, complete TAB "Process Matrix"
0
17
List any specific area(s) where this facility focuses.
What process and/or finishes does this facility have
expertise in, such as plating on plastics, aluminum
die cast finishing, etc?
0
18
Current manufacturing hours of operations (days per
week, shift per day, hours per shift)? Potential mfg
hours of operation?
0
19
How is overtime handled for the hourly production
workers? What extra support from engineering,
chemical analysis, waste treatment, etc is provided?
0
20
Amount of manufacturing floor space?
0
21
Amount of warehouse floor space? Is it dedicated
space?
0
22 0
23
24
25
Is there a Quality Manual? Make available upon an
audit visit.
0
2.0 Quality
subtotal =
1.0 General
26
For re-ocurring purchase orders, describe the
process for how orders are release to production.
What documents are used (travelers, follow tags,
setup sheets, etc)?
0
27
Explain traceability methods of product though the
operation. Are follow tags, travelers, etc used?
Provide a sample. What traceability is maintained
on the unplated material?
0
28
If workmanship quality standards are used, provide
examples. Explain how the standards are used and
how they are controlled.
0
29
Describe the calibration system. Is all equipment
tagged for identification? Is recalibration done with
internal or external resources? Who is responsible
for maintaining calibration compliance?
0
30
How are process check and inspection procedures
documented and used?
0
31
Are XRF units certified by the machine supplier?
What is the frequency? List any other equipment
periodically re-certified by an authorized outside
source? List authorized sources.
0
32
Are stereo microscopes used? What magnification?
Is there a camera system on the microscope?
0
33
List all other production test equipment is used for
inspection of product? 0
34
List any non-production test equipment "could" be
used for inspection and/or troubleshooting of
product?
0
35
If product requires multiple processes, describe any
product inspection between process and how
product is released to the next process.
0
36
Are inspection results added to a product traveler or
is there a separate inspection report document? If
separate, provide document samples.
0
37
Describe the Statistical Quality Control program.
What process parameters are tracked and
displayed? How is the data stored and used to
control the process?
0
38
Are retained samples (unplated and/or finished)
kept, and if so, for how long?
0
39
Are Certificates of Compliance used and provided
on every shipment? Provide a sample.
0
40
How is non-conforming material tagged and stored?
Is there an official designated non-conforming area?
0
41
Explain corrective actions procedures (8D?):
Describe the process for a customer complaint and
who is the point of contact?
0
42
Are in-house reject rates such as first pass yields
tracked? If so, provide details (pareto chart, etc) of
defect information.
0
43
Are external (customer) reject rates tracked? If so,
provide details (pareto chart, etc) of defect
information. What is the % rejection rate (by order
or part count)?
0
44
For at least the past 12 months, provide customer %
defects by either total part count or by number of
lots.
0
45
For at least the past 12 months, provide customer
details (pareto chart, etc) of the types defects
reported. If available, also provide numbers by
process.
0
46
Are dedicated (non-production workers) inspectors
or process checkers used? For non-dedicated
persons, what other responsibilities are held?
0
47
Communication: Are there "start of shift meetings" or
"between shift" meetings, etc.? Who leads the
meetings? Are there any specific goals or topics
always covered, such as safety, etc? Is this a
formal process including recordkeeping?
0
48
Are quality teams used? Who are the team
members and who leads the team? Briefly explain
their goals? Is there any recordkeeping?
0
49
Training: Is there a formal training/certification
program for production operators? Provide details
of job descriptions, skills checklists, training records,
etc.
0
50
Explain any on-going program of continuous quality
improvement. What LEAN initiatives, corrective
action, and/or preventative action are used?
0
51 0
52
53
54 Is there a documented NPI process? Describe. 0
55
Is there a documented change process for customer
or internal changes? Describe.
0
56
Are first time parts qualified using are FAI (First
Article Inspection) reports, PPAP, etc. Are the
qualified samples held in storage? How long are
samples and documentation retained?
0
subtotal =
2.1 "New Product Introduction" and "Product or Process Changes"
57
Provide examples of when Commscope would be
notified of changes in process, materials, or
specifications? (example: change plating chemical
supplier, etc)
0
58
What is the approximate (average) number of orders
processed per time interval, for the entire facility?
0
59 What is the approximate order turn around? 0
60 Approximate number of active part numbers. 0
61
Are customer part numbers given an internal part
number?
0
62 0
63
64
65
66
67
Describe any incoming inspection process? Are
records maintained and how?
0
68
Is there in-house inventory managed by an outside
vendor? Is incoming inspection different for these
materials?
0
69
Is there temperature and/or humidity control in the
storage area for unplated or plated product?
0
70
Describe the process if components do not meet
specification?
0
71
Are any unplated parts purchased, then processed
and sold to a customer?
0
72 0
73
74
75
Describe the incoming inspection process? How are
materials released for use in the process? How is
the inventory level controlled?
0
76
For specialty (proprietary) chemicals, list chemical
company names and their bath chemistry trade
name.
77
For specialty (proprietary) chemicals, is there local
technical support? How often is there a need for on-
site support and approximately when was the last
visit?
0
78 Is climate controlled storage used for any materials? 0
79
Is there a FIFO system utilized? Are expiration
dates monitored and documented?
0
subtotal =
Not a scored item
subtotal =
3.0 Materials
3.1 Unplated Components
3.2 Raw Material (Chemicals and anodes, other supplies, etc)
80
What security measures are in place for precious
materials?
0
81
Is cyanide used? What processes? How are
cyanide compounds stored and secured?
0
82
Are employees given RoHS/REACH training? Are
training records maintained?
0
83
Are any non-compliant materials used? List any
materials.
0
84
How is contamination control maintained and
monitored on non-RoHS compliant materials?
Examples would be containers, tanks, etc clearly
marked? Documented procedures? etc?
0
85 0
86
87
88
Is a CAD system used and if so, what system?
What formats are acceptable (iges, dxf, step, etc) for
files?
0
89
Does process engineering routinely provide DFM
feedback on a product?
0
90 Is there in-house tool design capability? Describe. 0
91 Is there in-house tool build capability? Describe. 0
92
Are toolmakers or machinists are employed? How
many?
0
93 0
94
95
96
Is there any unique customer tooling used? How is
this equipment identified and stored? Is any tooling
owned by the customer? Is any tooling
documentation is provided to the customer (by part
numbers, drawings, models, pictures, etc?
0
97 Describe any special storage for common tooling. 0
98
Can a list of all tooling used on CommScope
product be provided? Can tools be cross referenced
to CommScope part numbers?
0
99
Once a job is completed, what cleaning or
inspection is done on the tooling prior to placing
back into storage? If so, who is responsible for this
activity? Are records maintained?
0
100
Describe any preventive maintenance program (or
any periodic maintenance) for tooling. Is there a
regular schedule? Are repair records maintained?
0
5.0 Tooling (consider racks and barrels as tooling) and Preventative Maintenance
subtotal =
subtotal =
4.0 Design and Engineering
101
Describe the preventive maintenance program (or
any periodic maintenance) for the process
equipment. Is there a regular schedule? Are repair
records maintained?
0
102 0
103
104
105
106
107
Are process flow charts used? Provide samples of
any documentation.
0
108
What "standard operation procedures" exist?
Provide a list of the documents.
0
109
Is there a process document(s) for each customer
part number or process? Describe how is the
documentation controlled and used?
0
110
How are line setups verified for accuracy when
changing over to a new part and/or process?
0
111
Process tanks - Are all tanks and stations clearly
identified? Are NFPA diamond signs (hazardous
warning labels) or similar signage used?
0
112
Is there spill or leak containment protection
underneath tanks. Is there separate spill control
areas for strong acids, strong bases, cyanides, etc?
0
113
Are heated and primary (plating tanks, cleaners, etc)
chemical process tanks vented? Is pull-push
ventilation used?
0
114
For automatic lines, are there emergency pull cords,
and E-stop buttons?
0
115
Tank components (heaters, temperature sensors,
rectifiers, pH meters, etc.) Which components are
on automatic control? Which components are NOT
in the calibration system?
0
116
Is electrocleaning or ultrasonic part cleaning
available? Is oil skimming used on the alkaline
clean tanks? What parameters determine when
new cleaning baths are made up?
0
117
Solution filtering: Are plating tanks and/or other
tanks filtered? Continuously? Filter size? Turnover
rates? List chemistries which carbon treatment is
done.
0
118
Is dummy plating used? List any chemistries
continuously dummy plated or dummy plated on a
regular schedule.
0
subtotal =
6.0 Process
6.1 Plating Process
119
What is the source of the water to the facility and
what is the average water quality coming into the
facility? Is RO or DI used to clean up the incoming
water? What level of purity is achieved and where is
this water used?
0
120
Are dragout rinses used behind all plating tanks?
What quality of water is used to makeup dragout
rinses? Is dragout water used to replenish plating
tanks?
0
121
Is counterflow rinsing used in the process? How is
the water quality controlled on these rinses?
0
122
How is the water quality in the final rinse tank
controlled? Are conductivity meters used?
0
123
Is air agitation used in any process tanks? What is
the air source (compressed, blower) and is it
filtered?
0
124
Is air used in any part drying process? What is the
air source and how is the air quality controlled?
0
125
Is all routine chemistry analysis done in-house? If
not, what analysis is outsourced?
0
126
Is there always a chemist available during
production, even during overtime periods?
0
127
List equipment used internally for chemical analysis.
Are these used in a dedicated laboratory area?
0
128
What is the frequency of pH checks and plating bath
metal analysis? Is analysis provided during
production overtime work including any weekends?
0
129
Is there Hull cell capability? Is this used as a part of
the routine analysis and control? If so, describe
what is controlled, frequency, etc?
0
130
Are records kept of chemical analysis and
corrections? Is charting done and if so, on what
parameters? Provide a document sample.
0
131
Is any independent verification done on of any
internal testing? Can this be done and by whom?
0
132
Who is responsible for making chemical
corrections? Is any chemistry rechecked
immediately after the correction has been made?
0
133
Is whisker migitated, RoHS compliant, tin plate
provided? If so, what supplier/bath is used?
0
134
If precious metal is plated, how is precious metal
usage tracked (by line, by product, etc)?
0
135
Is there a commitment to housekeeping and
workplace organization? Is there a formal program
such as 5S? Describe the implementation.
0
136
Are packaging procedures documented? What
packaging materials are reused and how is oil, etc
contamination controlled?
0
137 0
138
139
140
Are any post-plating operations provided such as
machining, assembly, etc? List and describe.
0
141
Are there any other operations in the facilty such as
painting, etc?
0
142
Do you ship any CommScope product to 1) a 3rd
party manufacturer for additional processing or 2)
directly to a CommScope customer? If so, provide
information.
0
143 0
144
145
146
Does the supplier have a documented
environmental management system to ensure
effective planning, operation and control of
environmental aspects? Describe.
0
147
For on-site waste treatment and environmental
control, how are these activities monitored?
0
148
Are their any typical extended (one week or more)
production shutdown periods, such as during
Christmas or for long term annual maintenance, etc.
0
149
How is the facility monitored during shutdown
periods? What provisions are in place for
emergencies during such time?
0
150 Is there a disaster recovery plan? 0
151
What recycling programs are in place? Are there
any documented continous improvement programs
or goals?
0
152
Disposal of hazardous and non-hazardous materials
(liquids, solids-sludge, solids-filters, etc): Who has
responsibility for these activities? Are there
documented procedures for how these materials are
collected and stored, until they are disposed?
0
153 0
154
155
Comment on anything other value the supplier can
bring to CommScope which is not covered on this
audit.
6.2 Post Plating Operations
subtotal =
subtotal =
subtotal =
7.0 Environmental
156
Comment on anything regarding this audit
procedure, including any improvements which can
be made by CommScope.
Provide the following information in the below (or similar) format:
Equipment type Type (automatic/manual)
Barrel or Rack
size(s)
Qty
Capabilities (control
depth, spot plate, etc)
SAMPLE rack plating line manual 1 overall plate
SAMPLE reel-to-reel automatic 2 overall plate; spot plate
Provide the following information in the below (or similar) format:
Finish Specification
SAMPLE ASTM B 579 Nickel Plate
Base metals plated
Metals Plated or
special processes
Metals - Plating tank
size (quantity and
volume)
Current
Capacity
Comments
Zinc die cast such as
zamak 3.
copper, nickel,
electroless nickel
copper (500 L); nickel
(2 - 500 L);
electroless nickel
(250 L)
80%
copper alloys
nickel, hard gold,
ultrasonic cleaning
nickel (4 - 150 L),
hard gold (1 - 75 L)
75% ultrasonic clean available