Audit Plan: Auditee Eng/Support Top Management CC
Audit Plan: Auditee Eng/Support Top Management CC
Audit Plan: Auditee Eng/Support Top Management CC
PROCESS / LINE:
CTRL #: AUDIT TEAM
AUDIT TYPE: LEADER:
AUDIT DATE: AUDITOR:
AUDIT TIME: AUDITOR:
OPENING MTG TIME: AUDITOR:
OPENING MTG LOC: AUDITOR:
CLOSING MTG TIME: AUDITOR:
CLOSING MTG LOC:
REPORT ISSUE DATE: AUDITOR MTG TIME:
OPEN ITEM F/U DATE: AUDITOR MTG LOC:
AUDIT REPORT
CTRL #: 1/
REPORTED BY: [Associate preparing report] AUDIT SCOPE TIMEStart: Stop: Total: STEP 1 -- AUDIT / REPORT (AUDIT LEADER)
ISSUE DATE: [Date report is issued to auditee] COMPANY / PROCESS: [Company and/or Process being audited] QTYOK: NG: Total: PREPARED BY: VERIFIED BY: APPROVED BY:
1. 200PC / 2HR RUN (WHICHEVER IS
QAV2 REQUIREMENTS
AUDIT TYPE: [Type of audit (i.e. QAV1, QMS, Supplier)] PART NAME: [Part Name from Drawing/PQCT]
2. DOCUMENTATION LINESIDE AT
GREATER) WHO WHEN WHO WHEN WHO WHEN
AUDIT DATE: [Date audit was conducted] PART NUMBER: [Part Number from Drawing/PQCT] 3.
MPPROCESS
LEVEL EQUIPMENT AND FLOW
RESPONSE DUE DATE: [Date all responses are to be returned] MODEL YEAR / TYPE: [Model year and model type of part being audited]
4.
ATMEASUREMENT
M/P LEVEL EQUIPMENT IN
5. PROCESS RUNNING AT PLANNED
PLACE/QUALIFIED
COMPANY DEPARTMENT NAME POSITION AUDIT CRITERIA : [Standard to which audit is conducted (i.e. ISO9001, DWG# / REV, MPR's)] 6.
M/PPROCESS
RATE MEETS OEE QUALITY STEP 2 -- DEVELOP / IMPLEMENT COUNTERMEASURES (AUDITEE)
AUDIT TEAM
7. PRODUCTION
RATE TARGET ASSOCIATES FULLY PREPARED BY: VERIFIED BY: APPROVED BY:
8. MINIMUM ATTENDANCE
TRAINED
RESULTS SUMMARY: [Brief summary of audit findings] WHO WHEN WHO WHEN WHO WHEN
REQUIREMENTS MET
OVERALL JUDGMENT
ACCEPTABLE
CONDITIONAL - CONTINUE WITH CORRECTIVE STEP 3 -- VERIFY EFFECTIVENESS OF C/M'S & CLOSE AUDIT (AUDITOR)
ACTION
UNACCEPTABLE - CONTINUE AFTER CORRECTION
AUDITEE
PROCESS NAME /
VERIFICATION OF EFFECTIVENESS
NO. EVALUATION ITEM / CONTROL ITEM JUDGMENT 5P CTRL # JUDGMENT BASIS / CONCERNS CORRECTION WHO WHEN
"O" - ACCEPTABLE AS-IS; "D " - MINOR: CONTINUE WITH CORRECTIVE ACTION; "X" - MAJOR: CONTINUE AFTER CORRECTIVE ACTION COMPLETE.
INDIANA PRECISION TECHNOLOGY,
Inc. Document #: 09.03.01.01.10 Rev0 PG 14
AUDIT PLAN
AUDIT REPORT
CTRL #: 1/
PROCESS NAME /
VERIFICATION OF EFFECTIVENESS
NO. EVALUATION ITEM / CONTROL ITEM JUDGMENT 5P CTRL # JUDGMENT BASIS / CONCERNS CORRECTIVE ACTIONS (C/A) WHO WHEN
"O" - ACCEPTABLE AS-IS; "D " - CORRECTION REQUIRED; "X" - CORRECTIVE ACTION REQUIRED.
INDIANA PRECISION TECHNOLOGY,
Inc. Document #: 09.03.01.01.10 Rev0 PG 14
AUDIT PLAN
QAV REPORT
K= QAV # FROM QA.
QAV - 1/
REPORTED BY : A = NAME MODEL TYPE: E = MODEL TYPE STEP 1 -- INITIAL QA SURVEY (QA DEPARTMENT)
DATE: B = CURRENT DATE PART NAME: F = PART NAME PREPARED BY: VERIFIED BY: APPROVED BY:
COMPANY / DEPT. NAME: C = CO. OR DEPT. AUDITED PART NUMBER: G = PART NUMBER WHO WHEN WHO WHEN WHO WHEN
SURVEY DATE: D = DATE BEING SURVEYED Q.A.V. PURPOSE: H = REASON FOR QAV
Co. DEPT. NAME POSITION ISSUE
L = QA SIGNATURES FOR INITIAL AUDIT
STEP 2 -- DEPARTMENT RESPONSE / ACTION PLAN (DEPT. AUDITED)
"O" --ACCEPTABLE AS-IS; "P" or "D" -- MINOR CORRECTIVE ACTION REQUIRED; "X" --MAJOR CORRECTION ACTION REQUIRED.
INDIANA PRECISION TECHNOLOGY, Inc.
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Main Evaluation Overall
A
No. Sub Item Evaluation Item Objective Evidence
M
Category Judgment
4
Includes change point identification &
control?
5
Current revision easily visible to associate at
work station?
8
Pictures linked to process step & clearly
communicate requirement?
9
Q-Points, CAP's, A/G-Rank, Insp req's
identified using TGVF color guidelines?
11
Identify material/components for each
process?
12
Identify required tools/equipment for each
process?
13
PQCT control items requiring 100% visual
confirmation listed on WI's?
16
Clearly identify verification marking
requirements?
17
Matches PQCT (Process Name/#,
Spec's/Tol/UOM, Tools, Insp/Freq)?
Operation 18
Step-by-Step Set Up Operation Standard
Standards Available?
19
Step-by-Step Start Up Operation Standard
Available?
20
Step-by-Step Change Over Operation
Standard Available?
21
Step-by-Step Abnormal / Recovery
Operation Standard Available?
22
Step-by-Step Shutdown Operation Standard
Available?
INDIANA PRECISION TECHNOLOGY, Inc.
Document #: 09.03.01.01.10 Rev0 PG 2
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Main Evaluation Overall
A
No. Sub Item Evaluation Item Objective Evidence
M
Category Judgment
25
All check items listed on and linked to
PQCT?
28
Data in spec or identified and reacted to
appropriately?
29
Stored in designated location which
promotes retrieval & protection?
30
Quality Check Sheets - Include daily
management verification (min)?
31
Machine Check Sheets - start up & ongoing
verification, includes poke yokes?
32
Inspection Results Sheets - defect list
complete & clearly specified?
33
QC Audit Sheets - clearly states
requirements by shift?
34
Change Over Sheets - clear instructions for
each position?
2
TGVF created for each position current to
plan?
3
Training of measurement and test equipment
included?
5
Associates understand the critical features of
the product (Q-Points, A/G-Rank, etc.)?
6
Associates understand the function of their
process including Poke Yokes?
7
Associate performing work as specified on
Operation Standard?
8
Associates understand the use of quality
tools?
INDIANA PRECISION TECHNOLOGY, Inc.
9
Associates understand purpose of control
parameters?
11
Associates understand the consequences to
the customer of nonconformances?
12
TGVF completed for associate performing
operation?
14
Temp Associates in compliance with OD
requirements/restrictions?
2
In-process stations suitably prepared to
prevent handling damage?
3
In-process station promotes efficient
work flow?
4
Locator pins and fixtures facilitate loading
and do not create damage to parts?
6
Manual operations do not create damage to
parts?
8
Area clean, organized, taped off with
adequate tables, carts, storage space?
9
Cleanliness Standards developed for each
A-Rank position?
10
System in place to address shelf life
concerns where applicable?
Lot CTRL / 6
Lot identification system developed & utilized
PROD ID (scanner/LCS)?
8
Lot Control Sheets - lot information to be
recorded clear for each component?
10
Product identified early in process to
promote traceability?
11
Product properly identified with appropriate
tags?
12
Shipping Log - Includes Date, Shift, Lot #,
Qty, Associate ID?
Change Point 13
Similar parts separated to prevent
Control misassembly?
14
Model Change system exists to prevent
similar parts mixing?
15
Confirmation following model change
occurs?
2
Poke Yoke / Sensors / Interlocks working
properly?
5
Gages marked to identify operating range &
easy to read?
8
Bowl Feeders have visual display to
prevent mixing parts?
9
Bowl Feeder vibration frequency & fill
amount on PQCT?
11
W/o insert, load < low spec, and with
small hole, load > high spec?
12 Transducer Calibrated?
Adjustment /
Only Trained associates allowed to adjust
Abnormal 13
equipment settings?
Situations
Does the process stop if an automatic
14 process is not finished? Process
documented for restarting?
15
Downtime Sheet - key downtime issues
listed?
2
MT&E in calibration and in normal working
order?
3
MT&E accurate to extent required to assure
product quality?
4
MT&E available as specified on PQCT & at
WI's where measurements occur?
7
Masters identified with unique id and entered
into calibration system?
8
Masters able to control process through
upper and lower limits, OK and NG range?
10
Equipment stored in a manner / environment
suitable for their usage?
2
Suspect NG material is identified/tagged &
easily identifiable?
3
Suspect NG material stored in designated
containers (preferably red) /areas?
5
Nonconforming characteristic is clearly
identified?
9
Repaired product is marked / identified,
including lot control?
11
Repair / rework records include part no.,
date, shift & repair associate?
12
Reject and scrap records maintained to track
daily quantities?
13
Evidence of disposition, authority & records
maintained?
15
RIP Charts - developed according to KIM
standards?
5
Cycle time sufficient to allow complete and
thorough quality control checks?
6
Associates understand what each verification
mark represents?
7
Inspection verification marks match
requirements?
8
Packaging requirements are specified and
met?
2
Department TPM schedules developed and
maintained?
3
Maintenance PM schedule developed and
maintained?
4
Spare parts identified and maintained for all
critical processes?
5
Is product/process confirmed after
maintenance & prior to restart?
2
Capability level of data meets 1.33Cp/Cpk
requirements?
5
Management of appropriate area reviews
and approves data?
8
CMM programs verified by QA and PMR for
accuracy?
10
Masters available and functioning as
specified?
11
Masters Pass/Fail near tolerance
threshold?
2
Do control graph and drawing tolerance
bands agree?
3
Is statistically decided measurement used on
control graph for control line?
8
Is action taken when dot is above control
line?
9
Is process in control to minimize human
inspection?
10
Is action taken verified to be effective in
correcting abnormal condition?
11
Is record of actions being kept and is person
responsible confirming?
2
Is there a system to separate different
material types?
3
Is temperature of molten material
decided/maintained for each heat/lot?
4
Are periodic inspections of material
ingredients performed?
5
Is casting material temperature controlled
before entering mold for each heat/lot?
7
Is die temperature, flame & cooling rate
controlled?
8
Is correct gas and gas content after
degassing confirmed per lot?
3
Are die dimensions confirmed at new model
& periodically according to PM schedule?
4
Are dies maintained and repaired according
to PM Schedule?
5
Die lube and coating confirmed according to
schedule?
3
Are periodic inspections of die casting and
core measurements performed?
4
Are examinations for sand remaining in parts
performed to standards, if performed?
5
Are mechanical properties tested at New
Model Timing?
2
Start up Checks include: Quench temps,
concentration, flow, time & delay?
3
Process has alarms for temp, conveyors,
flow, fans and quench?
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A Main Evaluation Overall
No.
M Sub Item Evaluation Item Objective Evidence
Category Judgment
INDIANA PRECISION TECHNOLOGY, Inc.
Air blow / Washing process adequately
Machining General 1
removes coolant & contamination?
5
Tool pre-set list established? Collet/Tool
WI established / effective?
6
Tools numbered/identified by tool room
w/ regrind rules established?
7
Broken tool sensors present and in working
order?
8
BTS programming doesn't create abnormal
concern?
10
Equipment has a system to prevent
unauthorized machine adjustment?
11
Fixture has model type detection / poke
yoke?
12
Fixturing guarantees part presence &
position?
13
Machine / Fixture ID indicated on each part
for duplicate processes?
16
Is coolant, cutting oil & contamination
removed from part?
17
Are threaded holes and other small features
cleaned w/ dedicated wash nozzles?
2
Are necessary items for insertion conditions
confirmed?
3
Is relationship between insertion amount and
insert load clear according to data?
4
Are insertion conditions appropriate
according to data?
5
Is inspection of + diameter and - diameter
taking place of 100% guarantee?
7
Are concentricity and cylindricity measured
when controlling hole diameter?
8
Are appropriate measuring instruments used
to measure holes and jigs?
9
Is tolerance band for controlling insertion
conditions displayed at process?
10
Are insertion conditions controlled in way by
which size rejects may be detected?
11
Are measurements of functioning areas
controlled following insertion?
12
Is pull-out strength of inserted product tested
periodically?
13
Are important processes labeled as such
with signs?
14
Are associates allowed to manually insert
inserts (i.e. repair)? W/I available?
3
Are periodic checks of torque wrenches
done?
4
Electronically controlled torque equipment
has visual & audible alarm?
5
Equipment cannot advance part if torque not
achieved? (Required for A/G Rank process)
6
Equipment measures Torque and Angle or
Height?
7
Each assembly linked to its critical data?
(Required for A/G Rank process)
8
Product confirmation done at Beg/Mid/End of
each shift & during abnormal situations?
9
Quality Group confirms product torque 1/wk
(min) & during abnormal situations?
2
Is crimp dissection done to check for correct
shape?
3
Are crimp strength and crimp pull-off strength
tested?
4
Is measurement of article to be crimped
controlled?
5
Is tolerance band for crimp determined and
displayed at process?
7
Is measurement check of caulking height
performed?
9
Are important processes labeled as such
with signs?
10
Is use of sealing, bonding, and lubrication
agents specified and decided?
11
Are measurements of functioning areas
controlled following insertion?
12
Is pull-out strength of inserted product tested
periodically?
13
Are important processes labeled as such
with signs?