IATF 16949 9.2.2.3 - Manufacturing process audits

Hendor

Involved In Discussions
#1
Hi everyone,

My plan is to reduce the number of audits that are scheduled. I share a little of my current situation and some doubts.

Our bussines is metal stamping, molding and spot welding assemblies, for example we have 20 presses, 10 molding equipment and 25 welding cells. in total 55 work center (That is, I have 3 different manufacturing processes: Stamping, Molding, Welding).

My internal audit program (annual) for 9.2.2.3 manufacturing process audits. The programming and audit is by work center; that is to say, to the year they are 55 audits to the year (one for each press, molding equipment and welding cell) * In some cases the frequency is higher due to performance, risks, criticality, etc.).

My goal is to make this audit program light. In 9.2.2.3 The requirement as I understand it is to audit all the manufacturing processes, (and we have 3: Stamping, Molding, Welding).

Using this criteria can be 3 audits per year, one to each process. (They could be more in agreement with the risks, performance, etc).

From all this I have come some doubts that within the main ones are:

Is there a requirement that you are omitting me? (without thinking about CSR)

♦ How could a good sampling plan be applied? I have in mind something similar to this:
Stamping
2019 - Sample includes: Press # 1, # 3, # 5, # 8, # 10, # 15, # 20
2020 - Sample includes: Press # 2, # 4, # 9, # 13, # 15, # 19
2021 - Sample includes: Press # 6, # 7, # 11, # 14, # 18

♦ Taking this as an example: Should I include all work centers in the 3 year period?

I would appreciate your comments and apotaciones.
regards
 
Elsmar Forum Sponsor

QChas

Involved - Posts
#2
Hi everyone,

My plan is to reduce the number of audits that are scheduled. I share a little of my current situation and some doubts.

Our bussines is metal stamping, molding and spot welding assemblies, for example we have 20 presses, 10 molding equipment and 25 welding cells. in total 55 work center (That is, I have 3 different manufacturing processes: Stamping, Molding, Welding).

My internal audit program (annual) for 9.2.2.3 manufacturing process audits. The programming and audit is by work center; that is to say, to the year they are 55 audits to the year (one for each press, molding equipment and welding cell) * In some cases the frequency is higher due to performance, risks, criticality, etc.).

My goal is to make this audit program light. In 9.2.2.3 The requirement as I understand it is to audit all the manufacturing processes, (and we have 3: Stamping, Molding, Welding).

Using this criteria can be 3 audits per year, one to each process. (They could be more in agreement with the risks, performance, etc).

From all this I have come some doubts that within the main ones are:

Is there a requirement that you are omitting me? (without thinking about CSR)

♦ How could a good sampling plan be applied? I have in mind something similar to this:
Stamping
2019 - Sample includes: Press # 1, # 3, # 5, # 8, # 10, # 15, # 20
2020 - Sample includes: Press # 2, # 4, # 9, # 13, # 15, # 19
2021 - Sample includes: Press # 6, # 7, # 11, # 14, # 18

♦ Taking this as an example: Should I include all work centers in the 3 year period?

I would appreciate your comments and apotaciones.
regards
As an ISO Injection Molder with 28 presses, when we audit the injection molding process we look at a sample from machines (maybe 5 different presses). We do not audit all 28 presses. I also am interested in the response since we are in the preliminary stages of looking at IATF16949. Will we need to do 28 audits vs the sample of 5 for this process?
 

Pjservan

Involved In Discussions
#3
Your manufacturing processes need to include all the steps that are called out in your Control Plan, so you need to take that into account. THere is no requirement to audit all work stations but all processes within a 3 year schedule. Your plan ought to be design around the complexity, performance, risk, etc and customer requirements, of course.
 

Golfman25

Trusted Information Resource
#4
Following on Pservan. You can split your manufacturing audits into two types. What you have laid out is a good general manufacturing audit based on each work center to ensure each work center is doing the basics they are required -- everything is identified, paperwork filled out, etc. You an also do "manufacturing process audits" which will essentially follow a part thru Stamping, molding and welding (or whatever processes the parts go thru). There, you can pick a few parts per customer and audit those to the control plan. You'll pick up and customer specific issues that way as well. Good luck.
 

Rahul26692

Starting to get Involved
#6
I have come across a NC regarding laboratory personnel after testing material in our inhouse laboratory have not signed his testing report.

after asking i have found that he have just taken print outs and filed without signing .

So what should i give root cause, corrective action and preventive action for this ? please suggest
 

KimGr

Involved In Discussions
#7
I have come across a NC regarding laboratory personnel after testing material in our inhouse laboratory have not signed his testing report.

after asking i have found that he have just taken print outs and filed without signing .

So what should i give root cause, corrective action and preventive action for this ? please suggest

You have to figure out why he was just doing it that way (or didn't know he shouldn't) and what in your system allowed it to happen before you can figure out corrective action. Is there a procedure or work instruction? Is it trained?
 

Rahul26692

Starting to get Involved
#8
You have to figure out why he was just doing it that way (or didn't know he shouldn't) and what in your system allowed it to happen before you can figure out corrective action. Is there a procedure or work instruction? Is it trained?
Yes he is trained even though he has not done in that way. Procedure and WI are present but there is absence of signing authority after Report has been made.
 

Rahul26692

Starting to get Involved
#9
You have to figure out why he was just doing it that way (or didn't know he shouldn't) and what in your system allowed it to happen before you can figure out corrective action. Is there a procedure or work instruction? Is it trained?
Thanks for the reply
 

Jim Wynne

Staff member
Admin
#10
I have come across a NC regarding laboratory personnel after testing material in our inhouse laboratory have not signed his testing report.

after asking i have found that he have just taken print outs and filed without signing .

So what should i give root cause, corrective action and preventive action for this ? please suggest
Advice for the future: Rather than asking a question in a thread that's only peripherally related to your topic, you should start a new thread.

What you seem to be saying is that when asked why an unsigned report was filed, the person responded that an unsigned report was filed. That doesn't seem like an appropriate response to me. Some questions you might want to ask:
  • Before engaging in full-fledged CA, what are the risks involved? Is a simple correction all that's needed?
  • Are hand signatures really necessary? Is there a simpler way to indicate on the reports who the person was who did the testing?
  • Is it necessary to retain paper copies of test reports?
 
Thread starter Similar threads Forum Replies Date
C IATF 16949 8.3 Exclusion - Manufacturing process design and development IATF 16949 - Automotive Quality Systems Standard 5
J Manufacturing Process Auditor Requirements - IATF 16949 IATF 16949 - Automotive Quality Systems Standard 9
M Requirement for manufacturing process validation in IATF 16949 IATF 16949 - Automotive Quality Systems Standard 8
B IATF 16949 manufacturing cell in ISO 9001 factory? IATF 16949 - Automotive Quality Systems Standard 15
B IATF 16949 - Different Registrars for remote and manufacturing sites? IATF 16949 - Automotive Quality Systems Standard 2
V IATF 16949 Manufacturing Process & Product Audits IATF 16949 - Automotive Quality Systems Standard 1
M IATF 16949 Cl. 8.3 - Manufacturing process design and development IATF 16949 - Automotive Quality Systems Standard 1
S IATF 16949 - Manufacturing and Product Audit Approach IATF 16949 - Automotive Quality Systems Standard 19
M IATF 16949 - Cl. 8.3.3 - Product design inputs, manufacturing process design inputs IATF 16949 - Automotive Quality Systems Standard 4
L IATF 16949 Cl. 8.3.3.2 Manufacturing process design input - Process capability IATF 16949 - Automotive Quality Systems Standard 1
A IATF 16949 Cl. 8.3.5.2 e) - Manufacturing Process Flow Charts & Layout IATF 16949 - Automotive Quality Systems Standard 5
R Where does IATF 16949 address Process mapping? IATF 16949 - Automotive Quality Systems Standard 3
A Document "Correspondence IATF 16949 vs ISO13485" available? IATF 16949 - Automotive Quality Systems Standard 0
H Remote product audits in Coivd-19 - IATF 16949 9.2.2.4 IATF 16949 - Automotive Quality Systems Standard 3
S IATF 16949 - Partial traceability of Aftermarket products IATF 16949 - Automotive Quality Systems Standard 5
M IATF 16949 8.5.1.3 Verification of job set-ups - Do we need secondary check? IATF 16949 - Automotive Quality Systems Standard 7
C Industrial scales and MSA (IATF 16949 requirement 7.1.5.1.1) IATF 16949 - Automotive Quality Systems Standard 30
V Generic IATF 16949 Audit Checklist wanted IATF 16949 - Automotive Quality Systems Standard 3
M Scope of Combined ISO 9001 and IATF 16949 QMS - Non-automotive customers ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 5
D Postpone IATF 16949 audit due to COVID-19 IATF 16949 - Automotive Quality Systems Standard 33
J Does anyone have an excel IATF 16949 Internal Audit checklist I could use? IATF 16949 - Automotive Quality Systems Standard 7
T Reaction Plan To Drive suppliers to IATF 16949 registration IATF 16949 - Automotive Quality Systems Standard 4
B IATF 16949 - Is a Deviation required for sample components in a prototype build? IATF 16949 - Automotive Quality Systems Standard 13
C IATF 16949 - Scope or not? IATF 16949 - Automotive Quality Systems Standard 2
L "IATF-Compliant" IATF 16949:2016 certification? What does this mean? IATF 16949 - Automotive Quality Systems Standard 13
B Go Beyond ISO 9001 WITH IATF 16949 (January 28) [Paid] Training - Internal, External, Online and Distance Learning 1
V IATF 16949 8.4.1 Control of externally provided processes, products and services - Should the CB be on our Approved Supplier List? IATF 16949 - Automotive Quality Systems Standard 10
S Can we provide training plan as corrective action for IATF 16949 Non conformity? IATF 16949 - Automotive Quality Systems Standard 9
C Design and implementation of process audits as defined within IATF 16949 IATF 16949 - Automotive Quality Systems Standard 2
Q VDA 6.3 questions vs IATF 16949 clauses VDA Standards - Germany's Automotive Standards 0
N IATF 16949:2016 7.1.5.3.2 External Laboratory - How to approve the Testing Laboratory without accreditation scope IATF 16949 - Automotive Quality Systems Standard 1
M IATF 16949 (6.1.1 - Planning and Risk Analysis for a remote site) Process Maps, Process Mapping and Turtle Diagrams 5
D IATF 16949 FAQ 24 (8.4.2.2 Countries of Destination) - How is this actually being interpreted? IATF 16949 - Automotive Quality Systems Standard 3
Jimmy123 What is the difference between Error Proofing and Controls? ISO/IATF 16949 - Control Plans FMEA and Control Plans 16
P IATF 16949 8.4.2.4 Supplier Monitoring IATF 16949 - Automotive Quality Systems Standard 2
V IATF 16949 9.2.2.1 Internal Audit Program - "Process Changes" IATF 16949 - Automotive Quality Systems Standard 11
Sidney Vianna IATF 16949 News Presentations from the latest IATF Stakeholder Event - Expectation that IATF 16949 certification should equate with product quality. Misguided? IATF 16949 - Automotive Quality Systems Standard 7
J IATF 16949 8.4.1.2 Supplier selection process IATF 16949 - Automotive Quality Systems Standard 4
M IATF 16949 CAPITULO 7.3.2 IATF 16949 - Automotive Quality Systems Standard 3
Casana IATF 16949 7.1.5.3.2 External Laboratory - On Site Calibration IATF 16949 - Automotive Quality Systems Standard 8
M IATF 16949 7.2.3 Internal Auditor Competency - Trainer's competency Internal Auditing 7
P IATF 16949 Clause 8.4.2.3 - Justification for non-certified suppliers IATF 16949 - Automotive Quality Systems Standard 12
M IATF 16949:2016 clause 8.4.2.3 - We don't have ISO 9001:2015 certificate IATF 16949 - Automotive Quality Systems Standard 26
T New role Quality Manager IATF 16949, new company, advise how to get started IATF 16949 - Automotive Quality Systems Standard 2
R Material safety data sheet (MSDS) related clause in IATF 16949 manual IATF 16949 - Automotive Quality Systems Standard 17
R IATF 16949 Clause 8.5.1.6 a) maintenance and repair facilities - Production tooling management and personnel IATF 16949 - Automotive Quality Systems Standard 4
C IATF 16949:2016 Section 8.5.1.2 item d) accessible for use at the designated work area(s) IATF 16949 - Automotive Quality Systems Standard 5
QChas IATF 16949 Clause 8.5.1.2 - C -Standardized Work IATF 16949 - Automotive Quality Systems Standard 1
QMMike IATF 16949 Audit Day Requirements IATF 16949 - Automotive Quality Systems Standard 2
Crimpshrine13 IATF 16949 and ISO 9001 Remote Support - Pass Through Inventory IATF 16949 - Automotive Quality Systems Standard 20
Similar threads


















































Top Bottom