Manufacturing Process Audit Help

[Leetster]

Good morning Cove citizens,

I've been searching all morning on Elsmar and elsewhere and pulling my hair out over this. I apologize in advance if I'm hard to follow or misunderstanding key ideas, I'm new to IATF auditing and work for a small company with a lack of experience in the area. I'm trying to perform a manufacturing process audit according to clause 9.2.2.3 and am having trouble figuring out the best way to structure it. I've seen advice saying to follow the control plan and audit the steps outlined there (i.e. start with "process 2: secondary thread setup", audit that step, then move to the next one), and other advice stating it's necessary to audit the manufacturing process as a whole (i.e. starting with the first manufacturing step of screw machine setup and ending with secondary operations). I know the manufacturing process is okay, I just don't know how to prove it to an auditor. Thank you in advance for any help, and if anyone needs any more information or clarification please ask.

 

[Johnny Quality]

Leetster,

Just follow the process and acquire evidence that all is as it should be. You say the first step is "screw machine setup", how do you know what it should be and what evidence do you have that all is well?

Say a parameter has a range of X-Y as documented on file A in location B. Is B a sensible location? Is file A available and readable to the required personnel? Is it the correct revision level? Is the parameter within the range X-Y?

Document the pieces of evidence you used and what you see at the process.

 

[bkirch]

We walk the process using the control plan and work instructions as guides, and we maintain records of these audits. You may also look to see if any customer specific requirements apply. We have a few customers that require that we perform layered process audits which they state is a form of a manufacturing process audit. So we perform those as well.

 

[Golfman25]

First we do our manufacturing process audits at the part number level -- meaning we pick a single part number and follow it thru the process, which can take a week or more. We created a checklist, based off our our control plans. Then they walk thru the process from receiving material to final inspection. They verify each step is done properly -- paperwork signed off, inspection results reported, etc. We audit several parts per year.

 

[optomist1]

does your firm perform, or are LPAs (Layered Process Audits) required in your process, customer requirements?

 

[Leetster]

Thank you for your help everyone, I'll give it a go and report back.

does your firm perform, or are LPAs (Layered Process Audits) required in your process, customer requirements?

I don't believe we do LPAs right now, and we aren't required by any customers to do so at this time.

 

[optomist1]

Is your firm an automotive or "mobility" industry supplier?