DNV's Periodic Audit of our recertified Quality Management System for 2009 is now complete.
We had 3 days with a wonderful auditor from DNV. Some of the positives noted included:
Our production folks are extremely knowledgeable and are very versed in getting from the physical work they are doing back to the drawings, procedures and polices that tell them how and why to do it.
Our Product Development Control Process is commendable. The records for our most recent product release are so clear and organized that one of our new engineers ran through it for the auditor, since all of our project managers were out of the building.
All of the findings from all 2008 audits were reviewed and found to be effectively closed.
Only one finding against Document Control, Control of Non-Conforming Product and Corrective Action (a 3-fer!).
Corrective Action Finding
We have a Supplier
Action Request Form, with database. We use this to document single defects or returns even if we did not require corrective action as well as to document larger issues where we require Corrective Action. That's why it's call supplier "ACTION". There is a box to fill in a due date if corrective action is required. Unfortunately, somewhere along the line, our traffic manager started putting dates in the box even when the only action was a credit for the defective part.
Control of Non-Conforming Product
Some time ago, our Materials Team was urged to use their team meeting to review, update and close Supplier Action Requests in a timely manner. They found this to be such a good idea that they added a Part Action Form to track every single defective part until we had a resolution, whether it was credit, replacement, and/or corrective action. Unfortunately, the form comes with no instructions so the control is kind of fuzzy and records are a mess.
Document Control
I hope you can see this one coming. The new Part Action Form is not controlled, obviously. The instructions and form called out in the Control of Non-Conforming Product procedure is a Return to Supplier Form, a predecessor and very similar to the new Part Action Form.
The fix is rather simple:
- Tighten up the procedure to use the Supplier Action Form only when Corrective Action is required.
- Modify the Control of Non-Conforming Procedure to call the new Part Action Form when we do not request corrective action and include instructions.
- Create a Part Action Form Database and add this form to our released forms.
- Training all around for the users of the SAR Form and the PA Form.
A very good audit overall considering that since our recert 1 year ago:
- The only training, coaching, or realignment of people to procedures has been to answer the findings from the recert audit and the two internal audits (see above).
- The quality manager (me) was on medical leave for 3 months.
- We do no special clean up before audits. We just do what we do.
