ppqa titan pneus do brasil rev original

8/12/2019 Ppqa Titan Pneus Do Brasil Rev Original

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TITAN PNEUS DO BRASIL LTDA

PRODUCT & PROCESS QUALITY AUDIT

Based on Audit Revision 0

DATE:

AUDIT TEAM:

NAMES: SIGNATURES:

_______________________________________

_______________________________________ ___________________________________

___________________________________


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Area Week

Training & Communication 7/18/2011

Raw Materials, Mixing & Labs. 19 e 20/7/11

Component Prep 21 e 22/7/11

Truck 7/25/2011

Rear Farm & OTR 7/26/2011

Product &


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External PPQA 8/3/2011

New Tire Development 8/4/2011

Total

Outghoing Quality Audit


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14(0)

10(0)

291 (120)


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PendingNr of

OpportunitiesPending

o Brasil


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8/60


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Area WeekNr of Aplic.

Items% OK N N C Pending

Nr of

OpportunitiesPending

New Tire Development 10

Training & Communication 8

Raw Materials, Mixing & Labs. 40

Component Prep 54

Truck 27

Rear Farm & OTR 34

Curing & Final Finish 50

Monitoring & Lab. Testing 15

Warehouse & Shipping 8

Engineering Requirements & Calibration 31

External PPQA 14

291Total

Outghoing Quality Audit

Product & Process Quality Audit - Titan Pneus do Brasil


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NR NC Opp AreaQuestion

NrQuestion (check list)

Reviso: 01


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Description of nonconformity or

opportunity for improvementRoot cause and correvtive action Responsible

CORRECTIVE ACTIONS


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Final Date Status / Comments


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Area SubArea Ques# Question

Tire Release System.

4.1*Do tire releases meet requirements of GQMTS 19Rand the appropriate

S19R* (Subsections depending on specific product line)?

4.2 Is there a system for planning tire release activities?

4.3When 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?

4.1Is there a system to follow the performance of new tire codes and tune

as required?

No existe no check list de

offtake


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GUIDELINES

GQMTS 19R (and S19R* subsections for specific product lines) specifies the different releases applicable to new

They give detailed information on the tests to be performed and their frequency. Only tires meeting all the releas

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 i

There should be evidence of a visual display board (or equivalent system) detailing tire builds & ship dates (SOP

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"

committee has to meet when all test results are on hand for review. The formal signed release is given by the co

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-2017All Tire Lines: Production Tuning/Mon

This is done in the minimum of 2 weeks tuning phase. Records of the performance and tuning items must be av

code specific information.


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Training & Communication

1 Is there a machine operator certification system available?

5.1.6*Are critical elements which effect final product identified in the training

material for each area?

2 Is there a list of certified operators by machine type?

3Do training manuals exist for all functions in the tire rooms/curing/final

finish/ etc?

4 Are there designated labor trainers for each job or operation

5.1.1AIs there an initial machine operator certification system available for

contract associates (non-permanent labor)?

5.1.3Is there a system to recertify or verify operators on an annual bases

(SP procedures)?


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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 recordsAre 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, birthda

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 s

new training material?

Verify list of Certified Operators by machine typeIs 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)?


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Raw Materials, Mixing & Labs.

Mixing/Qual

& Labs

Mixing/Qual &

Labs6 Are routine audits being performed in the Mixing area?

6.1.3Is the CAR system used to notify supplier concerning issues of non-

conformance and is cost assigned systematically?

6.1.4Is there a procedure in place to evaluate raw materials and second

sources?

7Is there a documented system to receive, store and release raw

materials?

8 Are age limits followed?

9 Are release procedures being followed?

10 Are released materials correctly identified?

11 Are materials awaiting disposition correctly identified?

12Are incoming pallets of halobutyl and butyl marked or identified as being

incompatible?

13 Are storage conditions adequate and free from contamination?

14 Are incompatible materials separately stored in a well identified area?

6.2.2 Are only specified compounds, raw materials being used?

6.2.3Is there a procedure to introduce new compounds and compound

changes?

6.2.3aIs there a system to insure that changes to mixing specifications are

implemented correctly?

6.2.3.b Is automatic discharge system in place

6.2.4Are the correct workaway and disposition procedures being followed for

off test compounds/components?


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GUIDELINES


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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 C

Action Plan. Refer to QAI 2205

Review in SISCARCAR reports CAR cost summaryReview 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") w

to the last evaluation.

You must have documentation on your process to receive, store and release raw materials. The documentation must i

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

on the web (http://techweb/MaterialSpecs/agelimits.pdf). A gatekeeper (system or person) is required to ensure limits a

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 maknow the system. Randomly selected materials in production use must show they are probably released and within age

In storage and mixing production area, randomly checked released materials must have proper release ID (green stripe

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 curre

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 receiv

clearly identified as incompatible.

Raw materials should be stored in a covered area to prevent contamination. The storage area requires good housekee

wooden and cardboard pallets, strapping, etc. Materials stored in an open area outside without adequate covering resu

answer.

This area should have a sign stating only incompatible rubbers are stored here. It is preferred that this area have a col

painted on the floor/poles/walls to further identify it. There should be two areas (one in the warehouse area and one in t

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 d

Review procedure and records. Does it comply with requirements of GQMTSS19Q1

A system for mix spec changes must include: 1) How the new spec is introduced to the mixer operator and scheduler, 2

old spec is removed, 3) a method to record when the mix spec was active in production. The spec changes must incorpspec. 4) There should have a double check for all specifications, made by QTECH.

All mixing setup must include max mix time and temperature over-rideGQMTS P09C, CTI-055-11-00287There must be designated area for out of process (nonconforming material) and NO CURES. Workaway procedures m

GQMTS: S09E & P09Eor prohibited by a booksheet notes. Verify plant'sprocedure.

Check reformulation


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The operator must provide the following: 1) the schedule he is working from, 2) a run card (paper or electronic) show

compound name and serial, all raw materials (with tolerances), mixer RPM, ram pressure, ram raise times, oil injectio

black time, surge time, drop temperature, drop time. Some of these may be set by the control room in which case the

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 applic

(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,

Plants without age limits for blends and preweighed bags must put "NO". Age limits for non-productive rubber, scrap

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 batc

within tolerance.

There must be a separate area for incompatible compounds to be stored. They must be marked with red on the skid

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 tempe

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 corr

Bags are not knotted when loaded into mixer. If knots are used to close bags, they are cut out prior to loading on cha

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 requirem

Review plant procedure and verify against GQMTS P09E.

Compound physical properties are within the PPS limits and release limits (Rheometer 191C/200C). If release proper

consistently failing, the answer is "NO". If some low frequency testing is failing and there is a plan to bring them back

answer is "Yes". If no plan, the answer is "no".

For the Rheometer, calibration should be done per QAI2003which includes use of calibrated torque sta

PCPS plugs (ODR) and meeting the QA Premonth limits For RPA calibration should be do


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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?

32Do the alert / shutdown limits comply with specification ?

33

Are running cards posted at machine and being followed?

34Identification of extrudates?

7.1.1 *Do you have a QTECH procedure for regular inspection of all extruder

cooling lines?

7.1.2 *Is there documented evidence that the tank has been cleaned when

required?

7.1.3 Is there a cooling water temperature control system?

7.1.13Is water hardness audited at the frequency specified in Section 10N of

the GQMTS?

7.1.14Are 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 o


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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 Is component length within tolerance? (minimum 3/run)

7.2.2 Is component weight within tolerance? (minimum 3/run)

7.2.3 Is component width within tolerance? (minimum 3/run)

7.2.4 Is component contour within tolerance?

Mill Practices

7.3.1 Are mills properly loaded?

7.3.4 Are the cooling channels of the mills functioning per specification?

Comp PrepGum Cal

35Are compounds identified properly?

36Is compound age specified & observed?

37Are running cards at machine and being followed?

38Is the calendered sheet released according to spec?

7.4.5

Is there a compound traceability system at the gum calender and is it

effective?


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7.8.4 Is treatment / ply traceability adequate at the cutter?

7.8.6 Is treatment / ply angle correct at the cutter?

7.8.7 Is treatment/ ply splicing correct at the cutter?

7.8.9 Are gum strip/squeegee applications controlled properly at the cutter?

7.8.12 Is treatment storage adequate at the cutter?

Comp PrepBead Winding

60Is bead diameter checked / documented?

61Are beads properly identified?

62Are marking paint and cements properly released, ID'd & stored?

63Is bead compound (strip stock) retested (rheometer) prior to use?

7.9.1 Is the running card available at the bead builder and is it being followe

7.9.3 Is wire coverage good at bead winder?

7.9.6 Is there a good traceability system for beads going to tire room?

7.9.10 Is bead wrapping done properly and as specified?


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GUIDELINES


Is spec posted?Are checks being done according to the stablished frequency? Are results available to review? Are

inside the spec range?Is there evidence of corrective action? There must be a continuous monioring device, includ

system.

Is spec posted?Are checks being done according to the stablished frequency? Are results available to review, inclu

studies in case of using na indirect measurament method? Are the results inside the spec range? Is there evidenceaction?

Is spec posted?Are checks being done according to the stablished frequency? Are results available to review? Are

inside the spec range?Is there evidence of corrective action? There must be a continuous monioring device, includ

system.

Are procedures in place if alert limits are exceeded?Are components held for disposition? There must be evidence

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 do

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 expose

cooling?

Are results available for review?

See % solids/water hardness in GQMTS section 10N. Are components held for disposition if spe

exceeded?


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Is the tag retention system available and is being followed? Is correct identification on the tags and date of manufa

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

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

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 spec

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 avail

the 3 per run is waived.

Is the LMAC or profiler available and functioning? Are components released by contour? Is contour of released co

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 wo

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 batch

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 sta

tags? Is all batched-off compound properly identified?Are defective components being held-up at specified locatio

compound easily traceable?


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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

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 documented?

Is the traceability system available? Is it being followed?

Is the specification available to the operators? Is it being followed?


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Truck

Tire Bldg Tire Bldg65 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

Is there a process to check machine set-up and components at

beginning of shift and after every code change?

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 8.4.1

Are visual aids showing misplaced component effect on cured tire

displayed in the tire building area?


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Tire BldgBldg Inst 71 Are the correct quality requirements available to the operator?

72Are requirements for machine set-up correctly identified?

73Are latest set-up and running cards available to the operator?

74Is there a component traceability system?

75 Is the tire room directly notified in case of repeating defects and areactions taken?

76Are green tires/carcasses stored to prevent damage and distortion?

77Are age limits followed for green tires/carcasses?

78Are scrap carcasses / green tires properly segregated?

79Is there a system to follow code changes to insure tire codes are

started up correctly?

Tire BldgGeneral

80Is there evidence that specifications and run cards are being

followed by associates?


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GUIDELINES


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

traceability.

Review documentation, must include basic machine settings, component checks to dimensional requirements an

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

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 f

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,

must be revised and posted at the machine.

Documented measurements for critical parameters, as defined in plant control plan, should be available for revie

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 bein

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


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Has the operator been correctly instructed and are the quality requirements for his function clearly defined and ava

Each tire code has to have an up-dated and complete set-up card. This card has to be available to the machine a

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 r

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 t

marked with builder sticker.

In case of repeating defects occurring, the tire classifier or his representative should immediately inform the affect

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 damage

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

usage in the manufacturing process.

A written procedure for tire code changes should exist. All operators / service personnel / supervisors should be p

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 eq

settings.


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Rear Farm & OTR Y N

TT/OTR Laminadora STRIP LAMINATOR

7.13.1Is the correct compound being used and is there a

compound traceability system for the strip laminator?

7.13.2Are the drum and the program correct to produce the

tire?

7.13.3Is the tire weight being monitored according to the

established frequency and is within tolerance?

7.13.4 Are the tires correctly painted and identified?

7.13.5Are all the quality information required available to the

operator?

7.13.6Is the TCU in good working condition and controlling to

the specified temperature?

7.13.7Is there maintenance planned for the strip laminator and

is being done?

Tire Bldg Tire Bldg65 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

Is there a process to check machine set-up and components at

beginning of shift and after every code change?

8.3.9

Is there a system to identify and segregate nonconforming materials

and components?

8.3.12 Is component traceability effective?


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GENERAL

Transferir p/

OBT 8.4.1

Are visual aids showing misplaced component effect on cured tire

displayed in the tire building area?

Transferir p/

OBT 8.4.2

Is there effective communication such as video showing impact of

cause & effect of yield issues (performance issues)

Tire BldgBrkr Band Bldg

66Are the correct quality requirements available to the operator?

67Are requirements for machine set-up correctly identified?

68

Have age limits been established?

69Are age limits followed?

70Does segregation for off-spec bands exist?

Tire BldgBldg Inst

71Are the correct quality requirements available to the operator?

72

Are requirements for machine set-up correctly identified?

73Are latest set-up and running cards available to the operator?

74Is there a component traceability system?

75Is the tire room directly notified in case of repeating defects and are

actions taken?


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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.

specified frequency? Are weights taken documented? Are the tires segregated and corrective actions

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?


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?


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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 av

Each tire code has to have an up-dated and complete set-up card. This card has to be available at the machine a

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

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

identification on separate racks.

Has the operator been correctly instructed and are the quality requirements for his function clearly defined and av

Each tire code has to have an up-dated and complete set-up card. This card has to be available to the machine a

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

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 t

marked with builder sticker.

In case of repeating defects occurring, the tire classifier or his representative should immediately inform the affect

Records of these occurrences should be kept together with the corrective actions and subsequent results

Area SubArea Ques# Question GUIDELINES

C i & Fi l Fi i h Y N


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Curing & Final Finish Y N

Curing

ProcessCuring 81

Are routine audits being performed in the curing area? Is there documentation to verify these

General

9.1.4Is spotting specified?(Radial) Spotting should be specified for all con

9.1.5Is spotting being followed?(Radial) Confirm spotting is being followed.

9.1.8Is bladder pull policy established and being followed?

Is there a defined bladder pull policy t

is being followed.

9.1.10Is EQ identified, in good working condition and properly stored?

Updated EQ equipment inventories mu

inspection/condition of PCI rings. Mold

9.1.11*

Are shaping pressures correctly defined and monitored?

Is there a set-up sheet? Verify press s

at each mold change. If plant uses EO

press (one measurement every 2 seco

9.1.15Do all molds have a tracing or digital photo on file? A record of the tracing (or digital photo

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

stamping?

conforms to the Corporate Design Spe

chart, RACI chart, etc)

9.1.17*

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

A record that Mold Set-up Cards, and

Design Specification must be available

in service. Records must be maintaine

include signature of responsible assoc

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

correct?

A verification of the tire tracing versus

appropriate authorized associate), to

must be made within 24 hours.

9.1.21

Does the plant have and adhere to a mold cleaning cycle system?

Is there a written mold cleaning system

damage or missing slugs after mold cle

authorized?

9.1.23 Are appropriate corrective actions taken in response to world class

appearance standards (mold appearance and flash)?

Tires must be sampled and graded acc

2 or 3. Records must be maintained an

repair program.

9.1.35Are project cure audit results documented? Are project cure audits documented D


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83Are age limits followed? Verify that there is a system in place

84Is there a system in place to reduce/eliminate the possibility of loading

the wrong green tire in a press? Are there documented procedures/tr

85 Are the correct quality requirements available to the concerned

operators/ monitors?

Are the last revision of curing specs

graphs for services and tolerances p

86 Are requirements for machine set-up correctly identified? Are the set-up sheet posted on each

87

Is there a first tire system in place?

A system must be in place to check

tire sheet must be placed in a visible

running without a First Tire Check S

88Is there evidence that specifications and run cards are being followed

by associates? Question operators, review equipme

89 Are automatic or manual alarms for temperature/pressure in place forpresses, pot heaters and services?

Verify alarms are in place and in wo

reaction to the different alarm definequality known?

91Are the cures being extended for low green tire temperature?

Is there a written procedure/spec/run

procedure to measure green tire tem

Curing

Process

OTR Inserter

Oper92

Are requirements for machine set-up correctly identified? Is there a set-up sheet?

93Have green tire age limits been established? Green to cure limits must be specifie

94 Are age limits followed?

Verify system that identifies age of g

within age limits.

FinlFinish General 95Are routine audits being performed in the Final Finish area? Is there documentation to verify thes

10.1.7Are repair materials properly identified? Compound and cements must have

10.1.27*Is there a check tire procedure to check dynamic balance machine

accuracy? Review procedure (1X3) and data.

10.1.35*Is there a tire weight system in place? Review documented procedure.

10.1.42*Are correct limits being utilized for commercial tires being checked for

LRO/RRO/balance, and is the system being audited?

Pull a copy of the plant's grading cha

records to verify l imit tables are bein

FinlFinish

Prod

Test&Feedbac 96 Is there an inspection / classification system to insure compliance to


40/60


Warehouse& Shipping

FinlFinish Whse/Ship 108Are 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)?

110 Is there a system to trace and analyze customer returns?


41/60


42/60


43/60


44/60


45/60

9.1.28

Are green tires holders/pans aligned correctly with every mold change

9.1.46 re a r ven s an s eam raps on s eam ea er unc ona

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?

90 Are automatic cure extension timers in place and operational?

Final

FinishingFinal Finishing 10.1.6 Are repair presses and heaters calibrated?

10.1.32Are dynamic balance calibrations conducted as required with

documented results available?

Tire

Monitor&

Lab Testing

Tire Monitor&

Lab Testing11.1.7*

Is there a list of critical instruments which require calibration?


46/60

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 ba

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

on RPM's. This information can be found in Engineering Knowledge Database -Mixing /0004 How To...(Equipment)/R

dust ring oil and waste.

Each size banbury has Goodyear specifications for correct yoke pressure. This information can be found in EngineerDatabase - 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 b

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 corre

being taken and documented?

Is the schedule available? Is it being followed? Is the check being performed? Is the result documented? Is the corre

being taken and documented?

Is the schedule available? Is it being followed? Is the belt speed synchronization being performed? Is the result docum

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 actua

dates and results as well as the name of the checker. Eventual adjustments, repairs or replacements must be record

The instruments requiring calibration should be tagged with the instrument identification number, as well as next requi

calibration. Alternated ID placement optional (inlet line, door panel, etc) for situations not conducive to placing the st

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. A

bladder detectors and press combinations are being evaluated. As they are approved, they will be added to the requ


47/60

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.)

ev ew ea er a a er y a ar ven s an s eam raps are opera ona

All critical setting tools should be identified. A list should be available with an indication of the type and frequency

checks.

Accurate up-to-date calibration records of all critical instruments should be available at Calibration Lab. The reco

the actual calibration dates and results as well as the name of the checker. Eventual adjustments, repairs or repl

be recorded. Tolerance must be in line with GQMTS 16J1, review the plant procedure. Reference standards mu

national standards and up to date.

The instruments requiring calibration should be tagged with the instrument identification number, as well as next

calibration.

Is the PCI system in good working condition? Are the correct pressure and alignment set-up correctly?

anua y c ec a au oma c cure ex en ers wor 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 av

Testing (based upon QMS_ADM_CAL_0001 for North America plants or those plants referencing Goodyear's QM

PM 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

instruments requiring calibration. Required frequency of calibration checks should be part of the documentation.


48/60


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


49/60

13.26

Is there an active customer / dealer visit program?

13.28Are returned tires put on display and communicated to manufacturing

associates? Do all associates know the defectives that cause

adjustment? Are corrective actions taken?


50/60

GUIDELINES

For repeating defectives are there records that indicate corrective actions have taken place? Are there documente

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-2500and QMS_ADM_IAT_0001. Do the audit teams' audit results verify the p

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

for RFV, R1H and LFV and within 3 lbs of the limit for conicity. For RRO/LRO, undulation (bulge & valley), average10% 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/st ickers? For plants with bar codes and computerized inspection records in Fina

application of inspector stamps is optional (per Regional QTECH's direction, but computer records must be able to

and who inspected the tire. Any code selected as part of the OQL inspection that is not 100% compliant (with stam

bar code traceability) will be considered to have never been inspected and will be held for reinspection by the plan

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

b d?


51/60

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

are aware about the main causes of adjustment. Look for evidences of actions taken to solve adjustment causes


52/60

Serial Number:

Usage/Customer:

Barcode

INSPECTOR

STAMP

Force Mark

(Y or N)

(Leave blank if not

checked or not

required)

Balance Mark

(Y or N)

(Leave blank if not

checked or not

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

COMMENTS:

Spec Specs ===> x

!! The cells for the Spec values above

Serial Number:

Usage/Customer:

Barcode

INSPECTOR

STAMP

Force Mark

(Y or N)

(Leave blank if not

checked or not

required)

Balance Mark

(Y or N)

(Leave blank if not

checked or not

required)

X-Ray Stamp

MRT Only

(Y or N)

(Leave blank if

not checked or

not required)



Actual

Weight

Factory Code:

Factory Code:

TIRE SIZE/Type:

Plant : OUTGOING QUALITY AUDIT Date

TIRE SIZE/Type:


53/60

COMMENTS:

Spec Specs ===> x x


Serial Number:

Usage/Customer:

Barcode

INSPECTOR

STAMP

Force Mark

(Y or N)

(Leave blank if not

checked or not

required)

Balance Mark

(Y or N)

(Leave blank if not

checked or not

required)

X-Ray Stamp

MRT Only

(Y or N)

(Leave blank if

not checked or

not required)



Actual

Weight

RF

COMMENTS:

Spec Specs ===> x x


Serial Number:

Usage/Customer:

Barcode

INSPECTOR

STAMP

Force Mark

(Y or N)

(Leave blank if not

checked or not

required)

Balance Mark

(Y or N)

(Leave blank if not

checked or not

required)

X-Ray Stamp

MRT Only

(Y or N)

(Leave blank if

not checked or

not required)



Actual

Weight

RF

Factory Code:

Factory Code:

TIRE SIZE/Type:

TIRE SIZE/Type:


54/60

Barcode

INSPECTOR

STAMP

Force Mark

(Y or N)

(Leave blank if notchecked or not

required)

Balance Mark

(Y or N)

(Leave blank if notchecked or not

required)

X-Ray Stamp

MRT Only

(Y or N)(Leave blank if

not checked or

not required)



Actu

Weig

COMMENTS:

Spec Specs ===> x

!! The cells for the Spec values

Serial Number:

Usage/Customer:

Barcode

INSPECTOR

STAMP

Force Mark

(Y or N)

(Leave blank if not

checked or not

required)

Balance Mark

(Y or N)

(Leave blank if not

checked or not

required)

X-Ray Stamp

MRT Only

(Y or N)

(Leave blank if

not checked or

not required)



Actu

Weig

COMMENTS:

Spec Specs ===> x

!! The cells for the Spec values

Factory Code:

TIRE SIZE/Type:


55/60

!! The cells for the Spec values abov

Serial Number:

Usage/Customer:

Barcode

INSPECTOR

STAMP

Force Mark

(Y or N)

(Leave blank if not

checked or not

required)

Balance Mark

(Y or N)

(Leave blank if not

checked or not

required)

X-Ray Stamp

MRT Only

(Y or N)

(Leave blank if

not checked or

not required)



Actual

Weight

COMMENTS:

Spec Specs ===> x

!! The cells for the Spec values abov

Serial Number:

Usage/Customer:

Barcode

INSPECTOR

STAMP

Force Mark

(Y or N)

(Leave blank if not

checked or not

required)

Balance Mark

(Y or N)

(Leave blank if not

checked or not

required)

X-Ray Stamp

MRT Only

(Y or N)

(Leave blank if

not checked or

not required)



Actual

Weight

Factory Code:

Factory Code:

TIRE SIZE/Type:

TIRE SIZE/Type:


56/60


57/60

x

Static

Balance(MRT only)

x

Static

Balance

(MRT only)


58/60

Static

Balance

(MRT only)

x

Static

Balance

(MRT only)

x

Static

Balance


59/60

Static

Balance

(MRT only)

x

Static

Balance

(MRT only)

U if it S (I l di Ti W i ht ) Ti W i ht S


60/60

# over spec #Measured

Within

Spec

+0.5% and

Spec-1.5%

Greater

than

Spec+.5%

Less than

Spec -1.5%

RFV 0 0

RF1H 0 0

LF 0 0

Con 0 0

RRO 0 0

LRO 0 0

Undulation 0 0

Total Dyn Bal 0 0 # %

Static Bal(MRT Only) 0 0 Yes 0 #DIV/0!

TOTAL 0 0 No 0 #DIV/0!

Grades # % # %

0 #VALUE! #VALUE! Yes 0 #DIV/0!

1 #VALUE! #VALUE! No 0 #DIV/0!

2 #VALUE! #VALUE!

3 #VALUE! #VALUE!

Average ==> #VALUE! # %

OK 0 #DIV/0!

Illegible 0 #DIV/0!

Graded 2 Graded 3 Missing 0 #DIV/0!

# %

Yes 0

No 0

Inspector Stamps

Tire Appearance - Tires Graded >1

Reason

X-Ray Marking (MRT only)

0.0%

Force Marking

Appearance Summary Balance Marking

% 0.0% 0.0%

Uniformity Summary (Including Tire Weights) Tire Weight Summary

% Total Uniformity

Measurements withinspecs

# Tires 0 0 0

ppqa titan pneus do brasil rev original

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