Questions about process audits

[michu]

Hello everybody

I have a few question about process audit:
1. How often this type of audit should be performed?
2.Does the checklist should contains question related with PFMEA i Control Plan?
3.Does name "Process" audit is mandatory or can I named this audit in other way?
Thanks in advance for your help

[tabare]

michu, it would depend what you're doing process audits for. You might want to elaborate.

There are hundreds of process audit options out there.

[AndyN]

Originally Posted by michu

Hello everybody

I have a few question about process audit:
1. How often this type of audit should be performed?
2.Does the checklist should contains question related with PFMEA i Control Plan?
3.Does name "Process" audit is mandatory or can I named this audit in other way?
Thanks in advance for your help

There are many types of process audit discussed here in various threads at the 'Cove'. Could you give us some more details?

Are you thinking a 'quality system' process, like Purchasing?
Is it a 'manufacturing' process, like assembly?
Is it a 'layered' process audit?

Then we can help you out. You might also like to search the Cove because this kind of question must have been asked (tens of times) before!!

Thanks, Michu
Andy

[michu]

It's manufacturing process audit. By the way, could you explain me in short way what's the difference beetwen manufacturing process audit and Layered process audit

Thanks for help
Regards
Michal

[António Vieira]

Hi Michu


In my opinion, process audits can be done at least 3 or 4 times in each internal quality system audit. If you make a complete QMS audit only once a year, you can perform 4 process audits on each process of your system.
I perform this kind of audits using a check list that is completely based on the process specification. When in the specification or procedure is written one thing the check list has a question about it.
Normally I also have some general quality system questions like the employee functions and quality policy and objectives.
This check lists are always the same in each process audit. They have a scoring method that allows the quality area to check the improvement (or not) as long as audits are made to each process.
Many automakers use this scoring method of classification of their customers in 2nd party audits they perform.

One thing I’ve learned – the more process audits we make, the less nonconformances we have in QMS audits.

[Caster]

Originally Posted by michu

... could you explain me in short way what's the difference beetwen manufacturing process audit and Layered process audit

Originally Posted by michu

A layered process audit is something Chrysler came up with. Each layer of the company does a quick audit.

Foremen audit daily, supervisors weekly, plant managers monthly, and executives quarterly (for example). So each layer does an audit to be visible and demonstrate support and interest. Easy to say, hard to sustain.

LPA are a type of process audit.

[AndyN]

a manufacturing process audit uses the control plan and work instructions as the audit criteria, following the process flow chart 'down stream' or 'up stream'. A Layered Process Audit (both DCX and GM/Delphi have used them) is a check by 'layers' of management to see if work instructions are being followed (mainly since DCX, the loudest proponent of LPA's) don't utilize Control Plans as their suppliers do. The focus is getting 'issues' escalated to higher management to get them resolved.

Andy