well marc...read the rant and do not agree with the lack of OFI in Internal Audits.
So you want a few? well lets say first that OFIs don't always need to be major $$$$ process improvements, that said you may now agree?
1. An internal audit team (in training) audited the electronic assembly area of a client of mine. They noted that the operator was repositioning the components in the tray before assembly at stage 2. They asked why, and did the procedure tell them to do that. The answer was, they did it because it was easier for them to mount from that position, and they had less assembly mishaps (poke yoke?)...no procedure, just experience. The same team did stage 1, there they found that the operator was placing the units in trays in the same position as the stage 2 operator. When asked why, they stated that they used to work on stage 2 and knew it would benefit the process. Does everyone do that? What happened in the mean time? A cleaning process (not on the router or audit plan, just added to enhance stage 3 performance due to a contamination problem), the (new) operator there was just merrily plopping the units down as she went along...random positions. The OFI? Have the cleaning operation do the same positioning, make sure everyone is doing the same thing. the operators were thrilled that someone listened (value #1)...the efficiency and quality of less seasoned operators improved (value #2) All the auditors did was ask why...the area group leaders did the investigating and corrections as a result of answering the why's........An acceptance/applaud of the internal audit process by the manufacturing leaders (value #3)
2. During an audit of contract review, it was noted that all the information was in the files, but clumsy to walk through the trail of evidence to verify compliance. An opportunity perhaps? The auditee agreed, although compliant, even she had difficulty when the order came in verifying that the order met the original quote...she always did, and it was evidenced, but was very timely....So they created a summary form, and indexed the supplied data, and cut back her review time by more than 3/4
OFI yes..rocket science no.....but value none the less...and these were both from auditor trainees, during the training practice sessions.
As the company grows, so do the auditors, and so do the OFI.....Won't happen every day, every audit....but there will be a trend.