Number of mandatory questions questions

0
not filled in

18 0 1 2 fout

fout fout
How to fill it in?
Please fill in the Process Audit worksheet first.
The Summary score will be calculated automatically, but you have to fill in manually Conclusion and Comments.

How to fill in the Score cells in the Process Audit worksheet?

For each question choose between 5 scores from the in-cell drop-down menu that appears when you select the cell:
10 Fully documented & fully implemented
8 Not fully documented but fully implemented
5 Documented and not fully implemented
2 Documented but not implemented
0 Not documented and not implemented
Leave the cell blank if the question is not applicable - the 'N/A' cell will be changed automatically.
Every time you indicate a score that is different from 10, or you indicate a 'N/A' question, please comment and provide as much information as necessary.
Green marked questions are mandatory

How to determine the actions according to the Overall score?

D type supplier Not Qualified - Re Audit
< 65
C type supplier - Improvements Required Offline
< 75 - documents Verification .

B type supplier - Moved To Approved Supplier List

80˜90 ( Preadically Audit Conducted As per Plan

A type supplier - Approved Supplier - Audit Will Conducted as Per Plan /

< 90

Quality Mangement 98.3%

Pre Production 100.0%

Purchase 86.0%

Production 94.5%

Logistics 93.3%

Overall Score 94.4%

F/8.4/PU/03 , 02 ,30.03.2021
 General Information
Audit Date 1/20/2022

Electro Platers & Metal

Supplier Finishers

Location Ambattur

Scope Plating

Type System Audit / Process Audit / Product Audit

Need New Supplier Assesment / Yearly Review / Quality Issue

Frequency Quarterly / Half Yearly / Yearly

General Info Auditees

Number of Employees 75 Name Position

Shifts 2 Mr.Gurumoorthy Quality Incharge

Quality Contact Mr.Gurumoorthy Mr.Arun Kumar QA

Yahoo! Mail'
Email <[email protected]

Phone 9941652413

Assessment:

Performed by Mr.Kumar.R Performed by Mr.Ramprasath

Position QMS Position QA

For further Information Please Refer to the Current Supplier Profile Form.

F/8.5/PU/03 , 02 , 30.03.2021
 Supplier Audit Data
Supplier: Electro Platers & Metal Finishers Date Of Audit: 20/01/2022
Check
# Questions (tick)
Score Comments Proof

Quality Management R/U 98% Comments Photo/ Document Reference

Quality Management System is established, Documented

Does the supplier have an established quality management system in Quality Manual EMFPL/QM Rev.No.05 Dt.03-12-2019 and
1
place? R 10
Documented Quality Procedure EMFPL/QP Rev.No.01 Date.
###

01-02-2022 Are Available Evidenced.

ISO 9001:2015 CERTIFIED . Certificate Ref :

2
Is the quality management system based on a standard?
(ISO9001/ IATF16949 / ISO14001/ OHAS18001, Other...) R 10
BN15901/15694:1016 valid up to 26.10.2022
###

What are the results of the last audit conducted by the certified external
3 body? R 10
Last audit conducted by external agencies and 3 minor NC' s
are raised and all the nc's are closed
###
Audit report, observations, non conformities, time scale to solve

Internal Audit Conducted Periodically Once In Six Months,

4
Is an internal system audit program in place?
Review actual audits, non conformances raised, closures, time scales. R 10
Last Conducted On Sep'21 Evidenced
###

Are actual quality results and key performance indicators (KPI's) Quality Results and Production Performances Are Measured
5
measured and communicated to all personnel on a regular basis?
What are these communication methods (display boards, posters, white R 10
and Communicated to All Personnel Using Display Board .
MRM Conducted Once in Six Months Evidenced. Last MRM on
boards)? Oct'21 report evidenced

Customer documents are recorded in List Of External Origin

Is a system in place to document/ registration customer specifications
Documents LIS/D/06 Rev.No.06 Date.15-03-2021 .These
and ensure that these specifications are always used?
6 R 10
specification are used In auto line Barrel Process Specification
LIS/PS/10 Issue No.02 Rev No.05 Date.15.03.2021.New
The system should involve specification verifications for every new
manufacturing order verified through feasibility review check list
manufacturing order.
EMFPL/R/07 Evidenced.

Procedure available to handle the changes and followed .

7
Is there a clear (product) modifications system?
The system should show changed specifications (ECN, ECR) R 10
Still There is no changes happen and documents not
evidenced .
Ex: Change monitoring Sheet : EMFPL/R/24

8 Is there a process in place to handle customer complaints? R 10

Customer complaints are registered in customer complaint
register EMFPL/R/31 evidenced.

Are there problem solving methods used, such as 8D, PDCA?

Issues are analysed using QC tools with cross functional team,
Review a sample of supplier's corrective actions, check effectiveness of
9
problem solving with quality monitoring and check control plan has been R 10 standard 8D or customer format followed to solve the issue
evidenced.
updated.

10
Is the available measuring equipment sufficient to measure the produced
products effectively. R 10
XRF Spectrometer Available, Used To Measured Products
Coating Thickness And Alloy Content .

Has an adequate calibration program been implemented? Calibration status of Measuring and monitoring equipment
11 Calibrations traceable to internationally recognized standards, R 10 system ref LIS/D/ 08 rev.10 dt 15.11.2021 evidenced,
identification methods, procedures. calibration frequency once in year.

Are statistical techniques used, such as CP/ CPK/ Gauge R&R etc.?
12 Look for U 10 NA
records.

Is there a procedure in place to ensure that ISIR/ PPAP submissions are

PPAP Documents Are Submitted to Customer, There are PFD,
13 carried out in accordance with the customers requirements? R 10
Control Plan , FMEA, Checking Aid Evidenced.
Review ISIR and PPAP's submitted.

EMFPL / R / 18 . Process Parameter data storage in SCADA

Are all records/ data completed stored in an effective way? Is this data
14 accessible at any time? R 8
and backup for the same evidenced. PASSIVATION / TOP
COAT & DRYING Process Control Time Monitoring specific to
Check protection of data in case of emergency.
the process evidenced.

Pre - Production 100% Comments Photo/Document

Plating related standards available along with part drawings,

Customer reference standard and specification for. Part :
Are all the latest (customer) drawings and specifications internally
15 approved and distributed in a controlled way? R 10
Knuckle Fork Clutch Release Issue no.01 date.17-12-2019
evidenced. Customer documents are recorded and updated in
Should include disposal of obsolete documents
list of documents of external origin LIS/D/06 rev.10 dt
05.12.2021.

Control Revisions on Specification Evidenced Through

16
Is there a procedure to control revisions on specifications?
How are revision controls handled and communicated? R 10 Documented Quality Procedure Control Of Documents QP/01
Rev. No.0 Date.16-08-2016 Evidenced.

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 Supplier Audit Data
Supplier: Electro Platers & Metal Finishers Date Of Audit: 20/01/2022
Check
# Questions (tick)
Score Comments Proof

Are open engineering issues addressed with an appropriate action plan? Production process taken after getting approval from customer,
17 Especially important for running change issues. How is it ensured that R 10 defined in quality procedure Customer related process QP/08
engineering issues are finalised before actual production takes place? rev.01 dt 12.09.2018

Are clear procedures and containment plans on tooling approval and

Setup Approval / Patrol Inspection is in place? Production process is recorded in process control sheet and
18 Look for records and R 10 verified, defined in quality procedure Production process QP/11
measuring / approval forms. Is this process well documented? How are rev.no5 dt 11.1.20
customer approval requirements? ERP?

Does the Supplier have a System for managing & Storing Customer
19
Supplied Documents.
Aspects to check: measurement first sample, registration release, R 10
Customer supplied documents are recorded in External Origin
documents LIS/D/8 Rev.10 dt 05.07.2021.
methods to check, criteria of acceptance.

Documented Process Flow Evidenced For The Part Ball Pin

20
Is the process Flow well documented for each product?
If not for individual products then for general processes. R 10 Forging Knuckle Fork Clutch Release PRD/PFD/PRF/ 20 41 01
0533 Rev.No.0 Date.13-03-2021 Evidenced

PFMEA & Control Plan Available For All Product , Control Plan
PFMEA & Control plans for all component/ product?
21 Work instructions for production? R 10
Evidenced For The Part Ball Pin Forging Knuckle Fork Clutch
Release CP/QA/PRF 20 41 01 0533 Rev.No 01 Date.01-04-
Acceptance criteria and procedures for rejects?
2021 Evidenced.

Is sufficient machinery in place to carry out current production? Yes Sufficient Machinery is Available in place, List Of
22
Does the machinery in use meet the specifications of the product? R 10
Machineries LIS/D/09 Rev.No.09 Date.15-10-2020 Evidenced.

Preventive Maintenance Plan Available EMFPL/R/ 14

Is a documented maintenance plan, including preventive maintenance Evidenced. As per preventive maintenance daily ,weekly,
23 available to control machinery and tooling? R 10 monthly, and Quarterly checking parameter are followed.
Review machine, tooling, jigs & fixtures maintenance records. preventive maintenance evidenced Transporter T2 for the month
of Dec 21

Purchase 86% Comments Photo/Document

Is there an effective sub-supplier approval /control process in place?

Yes , Approved chemical supplier list available and verified
Approval criteria, sub-supplier audits. sub-supplier corrective action
24
requests.KPI's Material specifications, important dimensions and R 10 found evident .Total 5 Sub suppliers are available and managed
.
tolerances, restricted substances etc.

.Are Material & Product Specification supplied to sub-supplier.

Material specifications is communicated to supplier through Mail
25 Look for evidence in forms or R 10
or Purchase order , verified PO copy available and followed
reports.

Have all purchased components, materials and services from sub-

Material specifications is communicated to supplier through Mail
26 suppliers been approved by the supplier through a formal process? U 10
or Purchase order , verified PO copy available and followed
Check initial samples reports for each component and material .

Work Instruction For Incoming Inspection Available, WI/QA/09

Is there a valid procedure for incoming inspection? Rev.No 06 Date .01-12-2018 Evidenced.
27 Look for evidence in checking instructions, forms and records. Customer R 5 1) Incoming area to be rearrange with separate location with
supplied products must be handled as any other supplier. clear identification ( Plated parts & Non plated Parts )
2) Incoming inspection for chemical to be add in the control plan

Tag system and packing label followed to identify the material.

28
What measures are taken to indentify materials?
Check item number., revision, quantity, etc… R 8 1) Chemical acceptance sticker ( QC ok) to be improved for
visual identification before sending to the line .

Production 95% Comments Photo/Document

Are all personnel sufficiently trained and certified for their assigned Skill Matrix verified for the employees EMFPL / R / 04 reviewed
29
function?
How is it ensured that only competent personnel are working in the R 8
periodically, displayed in shop floor evidenced.
1)Training records , Training needs & Effectiveness monitoring
specified job role? Is there a training plan? system to be implement and followed .

Is there an effective identification/ traceability system in place from raw

materials through to finished product? Using Tags For Identification of Parts, Lot Code System
30 Check the trace from raw material/ component deliveries through to R 10 Followed For traceability System. Lot Code Verified For The
customer deliveries, material certificates. goods inwards control. Part Knuckle Fork Clutch Release V/F/D - 1 to 9
Are records of approval kept by batch/serial number?

Documented Quality Procedure For Production Process QP/11

What procedure is in place to release production when starting up? Rev.No.05 Date.11-01-2020 Evidenced.
31 Aspects to check: measurement first sample, registration release, R 8 1) Bath cleaning frequency to be mentioned in BMR sheet with
methods to check, criteria of acceptance. current date and next due date .( Anodic tank last done on
05.06.22 but check sheet not addressed)

Page 4 of 13 F/8.4/PU/03 , 02 , 30.03.2021

 Supplier Audit Data
Supplier: Electro Platers & Metal Finishers Date Of Audit: 20/01/2022
Check
# Questions (tick)
Score Comments Proof

Are work instructions made available for production and tooling, and are
they known by operators? Work instruction displayed near work area. Ref. WI/PROD/20
Check that they are in compliance with product requirements/ process work instruction barrel loading rev.no.01 date.11-01-2020
32
control plans. Do they adequately detail how to perform the operations R 10
evidenced. Operators Are Trained Product/Process Knowledge
and what to inspect? Is there clear evidence that the instructions have Training Record Available.
been checked on latest revision prior to production issue?

Process Control Record EMFPL/R/18, Electrolyte Analysis

Report EMFPL/R/17 Evidenced.
Are there registrations of measurements, during production?
33 Aspects to check: measurements samples, registration, methods to R 8
1) Calibration plan - location to be mentioned in all the
instruments and gauges for better identification.
check, criteria of acceptance.
ie : Temperature Controller J type identified and location not
mentioned.

Is the products status clearly indentified to ensure that only inspected

Documented Quality Procedure For Identification & Traceability
34 and released products are dispatched? R 10
QP/14 Rev.No.01 Date.12-08-2019 Evidenced.
Aspects to check: indentification on parts, boxes and documentation

Are all special characteristics (for example CTQ spec's) checked,

35 registrated and analysed. U 10 NA
Look for evidence in forms / documentation / procedures.

Is a segregation system in place for rejected material/ components?

Non confirming products are isolated , kept in red colour bin with
36 Check that bins are marked/ identified for easy identification, part R 10
identification tag.
labeling.

Rework part handling procedure defined in QP/19 16.08.2016,

37
Is a registration present for Reworked products?
How is traceability of reworked products communicated to the customer? R 10 work instruction available. WI/PROD/10 rev.no.02 date.15-09-
2021, replating details recorded evidenced.

How is the process monitored for effectiveness and are changes

38
implemented for improvement?
Use of SPC, process capability studies, kaizen events, 5s, feedback to R 10
Daily 5'S Check Sheet Available And Followed for all areas and
records verified found ok
engineering,...

Sampling Plan Available LIS/D/24 Rev.No.02 Date.12-08-2019

Is there a sample standard for incoming and final inspection, such as
39 sample size and sample frequency? R 10
Evidenced.
1) Yellow / Red Bin to be arranged in final inspection area for
Use of AQL or other sample check system
NG parts

Logistics 93% Comments Photo/Document

New product order confirmation process defined in quality

40
How is order in take controlled?
Order confirmation R 10 procedure customer related process QP/08 rev no.01 dt
12.09.2018

41
Does the supplier work on a FIFO system?
Check how they monitor dates and control sequence of usage. R 10
FIFO System Followed based on batch code, date of receipt
and records are maintained accordingly

Finished Parts with identification to prevent Mix-up. Dedicated

storage Area allotted for Finished Parts with proper
Are finished goods properly identified according to customer
42 requirements? R 8
identification. Packing Standard Available LIS/D/17 Rev.No 04
Date.15-12-2021 Evidenced.
Look for Customer specified labels etc.
1) Finish goods - WIP storage need to be improved with clear
identification

Customer wise Location Maintained. Separate Location for

43
What control methods are in place to ensure adequate storage of
component / finished product? R 10
Incoming / WIP / Finished Parts with identification to prevent
Mix-up. Dedicated storage Area allotted for Finished Parts with
proper identification

What measures are taken to protect materials/ products during

44 transport? R 10
Materials are kept in trays and bins, pallets. Trolley and material
handling equipment is using for material movement.
Internal transport

Tag & Packing label with lot code system followed For
45 How is traceability of finished products controlled? R 8
Traceability Of Finished Products

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 Photo's Audit

P 01 P 02 P 03 P 04

P 05 P 06 P 07 P 08

P 09 P 10 P 11 P 12

P 13 P 14 P 15 P 16

P 17 P 18 P 19 P 20

P 21 P 22 P 23 P 24

P 25 P 26 P 27 P 28

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 Photo's Audit

P 29 P 30 P 31 P 32

P 33 P 34 P 35 P 36

P 37 P 38 P 39 P 40

P 41 P 42 P 43 P 44

P 45 P 46 P 47 P 48

P 49 P 50 P 51 P 52

P 53 P 54 P 55 P 56

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 Photo's Audit

P 57 P 58 P 59 P 60

P 61 P 62 P 63 P 64

P 65 P 66 P 67 P 68

P 69 P 70 P 71 P 72

P 73 P 74 P 75 P 76

P 77 P 78 P 79 P 80

P 81 P 82 P 83 P 84

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 Photo's Audit

P 85 P 86 P 87 P 88

P 89 P 90 P 91 P 92

P 93 P 94 P 95 P 96

P 97 P 98 P 99 P 100

P 101 P 102 P 103 P 104

P 105 P 106 P 107 P 108

P 109 P 110 P 111 P 112

620700179.xlsx
 Opportunities For Improvement
Electro Platers & Metal Finishers
Item for Improvement nr: 1 Date:
Department:
Situation:

Improvement steps to make:

Planned date of completion: Date of completion: Verification QA:

Item for Improvement nr: 2 Date:

Department:
Situation:

Improvement steps to make:

Planned date of completion: Date of completion: Verification QA:

Item for Improvement nr: 3 Date:

Department:
Situation:

Improvement steps to make:

Planned date of completion: Date of completion: Verification QA:

Item for Improvement nr: 4 Date:

Department:
Situation:

Improvement steps to make:

Planned date of completion: Date of completion: Verification QA:

Page 10 of 13
Revision Date
00 02-06-2018
01 11/4/2020
00 3/30/2021

620700179.xlsx
 Change Details
New Release
Scope , Type,Need & Frequency Added
Check Sheet Review and Updated

620700179.xlsx
Wire Processing
Plating
ED Coating
Geomet Coating
Phosphating
Heat Treatment
Machining / Sloting

620700179.xlsx