Periodic Audit #4 for the last two days. Results:
Scorecards from customers are acceptable. PPM & delivery.
Internal metrics meeting company goals: KPI’s such as PPM, warranty, scrap, On time delivery, productivity, cycle count & financial data show positive trends.
Internal audit, corrective action system, & CI projects.
Team scoreboards , visual controls, & teamwork.
New product & technology, & marketing developments
Employee recognition, & communications
Main areas for improvement:
NC#1 Design change validation (7.3.6)
Requirement: Design changes shall be reviewed , verified , and validated, and approved before implementation. Records of results of reviews and necessary actions shall be maintained.
Failure: Not all design changes are fully recorded & validated , including actions before releasing to production.
Evidence: Units with incorrect error message drove an ECO 123 and change in Final test. The ECO does not describe the actions required before releasing to production, (e.g. validation of final test, work instruction update). The production line did not have record of authorization or updated instruction for final test on line. The test equipment was validated by EE and work instruction is currently being revised, but authorization of new final test was not on the line. The operator was testing it according to the ECO criteria for proper simulation.
NC #2 Work instruction availability
Requirement: Shall prepare work instruction & be accessible at work station
Failure: Work instructions are not always up to date with ECO requirements
Evidence: Final test work instruction was not updated for the ECO 123 test to simulate AGSP error codes. Note: an 8D was in place at this time and on line testing was being performed correctly.
OFI #1 Improve documenting target completion dates for action items on team meeting minutes
ARRGH!!! Two findings generated by the same Corrective Action that was implemented to detect the one failed diode out of 125,000 that we used last year.