Auditing Product Realization - Advice on common oversights to look for?

M

mshell

#1
I am preparing to audit our product realization process for the first time since completing the development of our QMS. I plan to audit the documentation this week and proceed to the various departments next week. I am going to follow the last two items that we put into production from Sales Quote to Shipment to the Customer. Do the experts have any advice on common oversights to look for?

Any feedback is greatly appreciated. :thanx:
 
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Wes Bucey

Quite Involved in Discussions
#2
mshell said:
I am preparing to audit our product realization process for the first time since completing the development of our QMS. I plan to audit the documentation this week and proceed to the various departments next week. I am going to follow the last two items that we put into production from Sales Quote to Shipment to the Customer. Do the experts have any advice on common oversights to look for?

Any feedback is greatly appreciated. :thanx:
Just to get everyone on the same page, here are three definitions for "oversight" - which one do you mean?
Definition:
  1. [n] a mistake resulting from inattention
  2. [n] management by overseeing the performance or operation of a person or group
  3. [n] an unintentional omission resulting from failure to notice something
Definitions 1 and 3 are similar, but completely different from 2.
 

Wes Bucey

Quite Involved in Discussions
#4
mshell said:
Definition 3
Look closely for operator activity NOT in the Procedure or Work Instruction as you follow the product through the steps. Catching these helps evaluate the sufficiency of the Procedure or Work Instruction versus "secret techniques" which, if present OR absent, affect the product quality.

Think of things as subtle as brushing off or not brushing off hanging burrs or checking things with an uncalibrated (uncontrolled) measuring instrument or not cleaning the anvils of a micrometer before measuring.

The concept should be:
  1. document what you actually do
  2. evaluate "actual" practice versus "theoretical" practice
  3. change actual or theoretical to provide best practice
  4. followup - does the change get followed?
 
G

Greg B

#5
Michelle,

I find the things that are sometimes missed are the 'links'. When you draw a process map you have a shape for each step of the process but lots of time people forget about the link between each sub process or the link between departments. 'Is the 'output' of my process the correct 'input' to the next process?' 'How did it get there?' 'Is it value adding?' 'Has it been reviewed?' 'Who is responsible for the transfer?' 'Who is responible for the product?' 'Does it need further storage or testing before it's next input?' There are many questions that could be asked but it would depend if you were involved in a line process or as I am a large multi level plant. Some of my auditors will audit the known process (Work Instructions or Procedures) but don't look outside of the box and ask themsleves "Where are the gaps?" They have to be tightened up and reviewed along with all other areas of the company. Product is now the responibility of the preceeding process until it is accepted by the next process inline. I hope this makes sense.

Greg B
 
M

mshell

#6
Thanks for the input. I will take a look at the items that you have mentioned. This is going to be the biggest audit of the year and I want to make sure I cover as much as possible.

:thanx:
 

Cari Spears

Super Moderator
Staff member
Super Moderator
#7
Wes Bucey said:
Look closely for operator activity NOT in the Procedure or Work Instruction...
..."secret techniques" which, if present OR absent, affect the product quality...
Good one, Wes.
 
Q

QCAce

#8
mshell said:
I am preparing to audit our product realization process for the first time since completing the development of our QMS. I plan to audit the documentation this week and proceed to the various departments next week. I am going to follow the last two items that we put into production from Sales Quote to Shipment to the Customer. Do the experts have any advice on common oversights to look for?

Any feedback is greatly appreciated. :thanx:
Find a report showing returns or complaints from customers.
This data might point you to some weak areas in the process and as you are reviewing the documentation, note some areas you will want to probe further into during your department audits.

Good luck.
Andy
 
M

mshell

#9
I have completed the majority of the Product Realizaton Audit and did find some improvement opportunities. I also found that we have a very knowledgable work force and that our documentation reflects actual practice (for the most part). I am working on the audit report this afternoon and will issue the CARs and observations next week. Thanks for the feedback. :thanks:
 
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