I couldn't find where I would begin a thread, so I thought I'd go this route.
Our company produces the pigments for glass, ceramic, plastic, etc. We're a Tier III contributor for Ford, GM and DaimlerChrysler. Our company downsized, and I am now the "lead" auditor; however, I'm not real familiar with each process center.
How do I process audit but still make sure I cover all the "shall's" in the standard?
Should I make lists of questions pertaining to standard for the Quality Manager then zero in on customer complaints?
Then make a list to take out to our production area to find inputs, outputs, SOPs, take a portion of an SOP and audit, a product from the area then follow it back through the process through customer service?
Would you happen to have any sample process audits that would give me an idea of how I should set them up and what I should look for?
At my last quarterly audit we switched over to a "process oriented audit" format and ran into the same concern you have (especially since I have a single audit format to audit two ISO9K2K facilities and one QS/TE facility). Our solution was to use a specialized interview sheet (attached below). We have close to 20 different processes, therefore 20 different customized interview sheets. Perhaps this will help a little.
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Rob - The sum of anecdotes is not data. -Roger Brinner
Thank you Mr. Atkins and Mr. Nix for your help. I appreciate the Process Audit Interview Sheet. The questions for our Manufacturing area actually cover exactly what you have outlined. I like the format that you have.
Once I complete my audit sheet, I am assuming I log it into my audit schedule. I listed my main processes (HR, Purchasing, Receiving, Manufacturing, etc.) across the top of an Excel spreadsheet along with the Manufacturing process areas (Requisitions, Tunnel Kilns, etc.) and the APQP, SPC, FMEA, PPAP and MSA. Vertically, I have listed each element of the standard. I will then put the corresponding report number into the corresponding box. It is divided into quarterly audits since we conduct Central Quality Committee meetings quarterly.
Does that sound like I've set it up properly or is it too much? If anyone has any suggestions, I would appreciate them. Thanks.
Last edited by Jodi G; 6th February 2004 at 12:22 PM.
Reason: Additional Question
How do I process audit but still make sure I cover all the "shall's" in the standard?
#1 - You do not have to cover all the shalls of the specification in a process audit. There are three types of audits required; QMS, Mfg. process, and product audits.
#2 - Attached is a "turtle" diagram that can be used to determine the contents of the process. Even if the process is already eastblished you can use this tool to familiarize your self with the process.
#3 - Once you are familiar with the process, use the tool that Rob attached for your audit.
I previously posted a question as to my audit schedule. I think it's a little overkill. I think what I'm doing is reading too much into it to make sure I cover ALL bases.
Would there happen to be a list showing the process area of, for example, Purchasing, and which elements are applicable to it? Then, one for HR and its applicable elements, etc.
Our company produces the pigments for glass, ceramic, plastic, etc. We're a Tier III contributor for Ford, GM and DaimlerChrysler. Our company downsized, and I am now the "lead" auditor; however, I'm not real familiar with each process center.
Out of curiousity, Jodi, have you had any formal training to be a Lead Auditor? Some of your questions could probably be answered if you attended a Lead Auditor course (i.e., process-based approach, developing a suitable schedule, etc.).
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~ Roxane ~
"There's a fine line between genius and insanity. I have erased this line." - Oscar Levant
No, I haven't taken the Lead Auditor course, only the Internal Auditing with Emphasis on ISO/TS. Actually, I took the class in Dec '02. Our 3rd party TS auditor required that I retake the same class in Dec '03 because Ford changed their Internal Auditor requirements. There was no one on site who was qualified to audit to TS.
He actually recommended I take the Lead Auditor course during 2004.
New to Internal Process Auditing
Thank you Mr. Atkins and Mr. Nix for your help. I appreciate the Process Audit Interview Sheet. The questions for our Manufacturing area actually cover exactly what you have outlined. I like the format that you have. 
Once I complete my audit sheet, I am assuming I log it into my audit schedule. I listed my main processes (HR, Purchasing, Receiving, Manufacturing, etc.) across the top of an Excel spreadsheet along with the Manufacturing process areas (Requisitions, Tunnel Kilns, etc.) and the APQP, SPC, FMEA, PPAP and MSA. Vertically, I have listed each element of the standard. I will then put the corresponding report number into the corresponding box. It is divided into quarterly audits since we conduct Central Quality Committee meetings quarterly. 
Thank you for your assistance! 
I previously posted a question as to my audit schedule. I think it's a little overkill. I think what I'm doing is reading too much into it to make sure I cover ALL bases.
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