QUALITY SYSTEMS BASICS AUDIT

EVIDENCE REQUIRED LOOK FOR COMMENTS

SCORE R/Y/G

LAYERED PROCESS AUDITS

Is there a system in place to verify the documented manufacturing/assembly process through layered audits?
A defined Layered Process Audit procedure that is owned by manufacturing. 1) 2) 3) 4) Written Procedure Audit & work instructions Counter measure process Owned by Manufacturing

All levels of the organization participate in Layered Process Audits at established frequencies.

1) Audit Schedule showing level of participation and frequency. 2) Evidence that ALL layers of the organization perform regularly scheduled standardized audits. Plant Manager should be monthly, Shift Leaders and Management Support Staff - Weekly, Group Leader-Team Leaders-Daily. 3) Tracking to ensure every work station is evaluated on regular basis. Audit Check sheet includes: 1) Quality Focused checks for past customer failures. (i.e. Assigned Workstation, Quality (Customer Focus), at Fast Response, for PRR or Liaison Report issues, error-proofing and System high risk items. verification, etc...) 2) Workstation Specific check items (Review of actual work performed by Team Members to standardized work instructions, 5S-WPO, Rotation Log, Training, etc..) 3) Work Station and Quality Focused items are checked by all auditors. 4) System Specific items (Preventative Maintenance, Business Plan reviews, Shop Floor Management standards, etc..) Process specific audits are performed (CQI 9, 11, 12, Weld Audit, Chrome Audit, Paint Process Audit etc.) System to review and document the results of the audit. 1) Verification in the Layered Process Audit under system specific items that, where applicable, Audits for special processes are performed. 1) Results reviewed with team members & area supervisors 2) Evidence and documentation of immediate corrective action for nonconformance. (Items corrected immediately) All deviations are recorded on the check 3) Countermeasure list with responsibility and dates for items that sheet. could not be corrected immediately. 4) Review of counter measure process at least once per week. 5) When appropriate nonconformance is added to Fast Response or C.A.R.E. BEST PRACTICE: Check that the Audits are verified by the next level Supervisor. Addition of Layered Process Audit issues to the Lessons Learned system. Audit results are summarized and reviewed by manufacturing site leadership. 1) Lessons Learned system, documentation.

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1) Reports or graphics that are reviewed by management.

R R
28

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SCORE / POTENTIAL 0

QSB Audit form 07.04

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Rev 20090213