Audit Technique to find rework in a process area?

eternal_atlas

Involved In Discussions
#11
I completely agree with Randy,

Also,

How about looking at the records of checks, tests and inspections done on the product. If the product (or intermediate product) did not match the criteria, what was done - was there a re-work? Look at your procedure of Control of non-conforming products. What happens in the event of a non-conforming product?

IMHO considering your promise of reducing rework, it will be better to have a system of collecting and analyzing such data periodically and look at the trend. Then further deciding on the action for progress in desired direction. Looking for such data / evidence in internal audit may not be very effective. You have talked about reducing rework, not eliminating, yet.
Good point.. let us address this in our control of nonconforming product.. Thank you..
 
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J

JaneB

#12
Re: Audit Technique to find out the rework in a process area?

2. Instead of honesty, employees are getting scare of audit due to the management reviewing each line of the audit report and its reaction affects their promotion and bonuses.
3. Paper trail is very difficulty, since we hidden factories are more here.. everybody wants to hide the mistakes..
If my management was using 'each line of the audit report' to affect my chances of promotion and bonuses, I think I'd be hiding my rework also and quite possibly avoiding honesty!

If audit is being used as a punishment or shaming tool, there could be a problem within the system or the management of it.

One of the fundamental principles of quality is involvement of people at all levels. I'd definitely be seeking ways to get people involved in the problem of rework (if there is one) and seeking to address the WIIFM? (what's in it for me?) question. Because if there's no upside for them, only downsides for honestly reporting, why would they??

Using mistakes/problems as opportunities for genuine improvement (not blame & punishment) is essential for real improvement. And the hallmark of a company further up the maturity scale in relation to quality management. Hang 'em high only works in the very short term, usually. And has various other negative consequences.
 
Last edited by a moderator:

somashekar

Staff member
Super Moderator
#13
We have a quality policy to minimize rework in all process areas. But,when we go for audit, we find difficult in identifying the rework happened in that area. The reason is, auditee are very defensive which makes me to dig out to the core to find.. even in construction process are also, we got the answer there is no rework..

My question is :

1. Do you have any audit techniques to reveal the rework areas during audit?
2. What are the potential areas of rework irrelevant to the process areas?
I guess if your policy directs the objectives, then perhaps the First Pass Yield of your identified processes must be one of your main measureable objective. Improvements continually in achieving the 100% FPY and steps taken on drop in any of this yield can be your audit focus.
Any thoughts on this >>>
 

antoine.dias

Quite Involved in Discussions
#14
Why not check the outcome of the process by conducting O.E.E. ?

This way you not only have the rework but you have an overview of the waste in general.

Best regards,

Antoine
 

eternal_atlas

Involved In Discussions
#15
Shekar,

Could you please define the rework? FPY most applicable only to manufacturing industry or to your medical devices manufacturing industry..what abt electromechanical industry..
 
Last edited:

Stijloor

Staff member
Super Moderator
#16
Shekar,

Could you please define the rework? FPY most applicable only to manufacturing industry or to your medical devices manufacturing industry..what abt electromechanical industry..
Anytime a product (or whatever it is you provide to the customer) is found to be nonconforming, and an attempt is made to repair/correct it to bring it back into the specifications, it is considered rework.

Stijloor.
 
B

Bob Bonville

#17
Reasons for rework are not always directly related to the individual performing the job. They could have had poor direction, instructions, materials or equipment with which to perform the job. These things need to be identified so they can be addressed through the Corrective Action System. Remember, in most cases it not the person it is the process.

Bob Bonville
 
J

JaneB

#18
Reasons for rework are not always directly related to the individual performing the job. They could have had poor direction, instructions, materials or equipment with which to perform the job. These things need to be identified so they can be addressed through the Corrective Action System. Remember, in most cases it not the person it is the process.
Yes, absolutely. Hence the importance of looking for real root cause(s), not just the easy path of assigning blame. Which is just about guaranteed to turn people off 'quality'.
 
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