ASTM B32 grade identification Material grade, revision, and product form stated in the technical offer | Pass Grade and applicable ASTM B32 revision identified; alloy designation matches the purchase specification. | Conditional Grade stated, but the revision and permitted composition limits require confirmation. | Pass Grade, product form, and inspection basis are listed in the quality plan. | Incomplete Only “commercial tin bar” is stated; no ASTM B32 grade is defined. |
Chemical composition evidence Heat or lot number, certificate of analysis, and independent test traceability | Heat number linked to the bar batch; laboratory certificate includes Sn, Sb, Cu, Pb, Bi, and impurity results. Third-party verification available on request. | Supplier laboratory report supplied for each batch; test method and instrument calibration record are not attached. | Independent laboratory report provided for the pre-shipment sample and cross-referenced to the melt number. | No lot-specific chemical report included in the quotation package. |
Melt temperature control Measured furnace operating range during FAT | Set point 280°C; recorded operating range 278–282°C over a 60-minute stability test. | Set point 285°C; recorded operating range 280–289°C over a 30-minute test. | Set point 275°C; recorded operating range 273–277°C over a 60-minute stability test. | Temperature range not recorded; only a controller screenshot was provided. |
FAT documentation Approved procedure, signed checklist, raw data, and punch-list closure | Pass Procedure, checklist, video evidence, raw measurements, and signed punch-list closure included. | Conditional Checklist and photographs provided; raw measurement records are incomplete. | Pass FAT protocol includes safety, heating, cooling, drive, lubrication, and product inspection sections. | Incomplete General inspection summary supplied without an approved FAT acceptance matrix. |
FAT production run Continuous operating demonstration under agreed load | 8-hour continuous run completed; no unplanned stoppage; product discharge remained stable. | 4-hour run completed; one manual reset was recorded during the cooling-cycle test. | 8-hour continuous run completed; no critical alarm or drive trip recorded. | 2-hour no-load demonstration only; production-load endurance was not demonstrated. |
Bar length tolerance Contract acceptance criterion: ±2.0 mm from nominal length | Measured range: −0.8 mm to +0.9 mm; 30 samples inspected. | Measured range: −1.6 mm to +1.8 mm; 20 samples inspected. | Measured range: −0.7 mm to +0.6 mm; 30 samples inspected. | Measured range: −2.4 mm to +2.7 mm; corrective action required. |
Bar cross-section tolerance Contract acceptance criterion: ±0.5 mm on width and height | Width deviation: ±0.24 mm; height deviation: ±0.21 mm. | Width deviation: ±0.43 mm; height deviation: ±0.46 mm. | Width deviation: ±0.18 mm; height deviation: ±0.20 mm. | Width deviation: ±0.72 mm; height deviation: ±0.65 mm. |
Surface quality inspection Visual check for cracks, cold shuts, excessive oxide, and sharp flash | 30 of 30 samples accepted; minor removable flash recorded on two samples. | 28 of 30 samples accepted; two samples showed visible surface porosity. | 30 of 30 samples accepted; no visible cracks or cold shuts. | 24 of 30 samples accepted; recurring oxide inclusions were recorded. |
Dimensional measurement system Calibration status and measurement method | Calibrated digital calipers and micrometers used; calibration certificates were valid on the FAT date. | Digital calipers used; calibration certificate was available but due for renewal within 30 days. | Calibrated micrometers, vernier calipers, and a temperature-controlled inspection area documented. | Measurement tools were listed, but calibration status was not demonstrated. |
Process traceability Link between raw material, machine settings, inspection records, and finished bars | Complete traceability through heat number, recipe, machine settings, inspection lot, and packing record. | Traceability available from inspection lot to packing record; furnace batch link requires improvement. | Complete electronic and paper traceability system demonstrated during the audit. | Manual packing records only; furnace and inspection records could not be linked reliably. |
| Overall engineering audit result | Recommended Strong document control, repeatable FAT data, and dimensional results within the stated acceptance criteria. | Conditionally Recommended Acceptable performance, subject to closing calibration, raw-data, and temperature-stability gaps. | Recommended Best overall evidence package and the tightest demonstrated dimensional control. | Not Recommended Insufficient ASTM B32 traceability, limited FAT coverage, and dimensional results outside the stated criteria. |