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Product Audit Planning / Frequency /Scope - Is anyone aware of preferred methods?

Boro Col

Starting to get Involved
#1
Is anyone aware of preferred methods of planning product audits (i.e. how many product types/ customers per annum)?

Currently working with company that has over 30 product types spread across several automotive customers. Batch sizes are relatively small and infrequent.

Can anyone offer practical guidance on this matter?

Am considering scheduling one product audit per month with the aim of covering spectrum of generic parts manufactured - would this be acceptable to a TS16949 3rd party assessment body?
 
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Marc

Hunkered Down for the Duration with a Mask on...
Staff member
Admin
#2
Is anyone aware of any related TS 16949 requirements? I'm not off hand.
 
M

Myriam

#3
We are a QS9000 certified company (still), and TS16494 audit is scheduled for March this year. Therefore I am not completely sure this will be accepted by a 3th party audit; but for QS9000 it was accepted and we will not change it for the TS.
We base our product audit frequency on the customer complaint evaluation results and other audit results. At first we had a frequency of once per month. Actually 12 per year, because if we skip one month for whatever reason we can perform two in the next month.
We specified 12 per year because the number of complaints has improved (decreased) drastically, and also the impact of the compaint-product to the customer improved quite a lot, and therefore we were confident that the process is under control.
During last year as a result of the product audits and a serious customer complaint we decided to perform extra product audits on one production item.
So, in my opinion you can decide to perform product audits at some frequency your self, if you are confident that for your company once per month is OK, you should do so; and if concidered necessary you can allways change the frequency.

Myriam
 
V

vanputten

#4
8.2.2.3 Product Audit

I beleive Boro Col is asking for help in meeting the requirements in 8.2.2.3 Product Audit of TS 16949.

We have always used our inprocess inspections and final inspections performed by the quality department which is independent to the inprocess and final inspections performed by product realization employees.

We don't do a formal "Product Audit." We decided not to do this becasue the internal auditors did not know all of the product dimensions, functionality, etc. The internal auditors would have had to ask for help from those that perform the product inspections anyway. We decided that a Product Audit performed by the internal auditors was not a value added activity.

Regards,

Dirk
 
M

Myriam

#6
Dirk, I understand your reply. With our company it is also the case that internal auditors do not know all product dimensions etc, and tests are performed by independend inspectors.
Nevertheless we perform product audits, and amongst other items a sample taken by the internal auditor is tested by the laboratory.
A product audit for us is verifying conformity to all (customer) requirements, so we take the original order/ contract and we audit if the customer specific requirements are implemented correctly in the organisation for this product. e.g. are the dimensions etc the inspectors are working with the correct ones, do they have the last revision adn are they working according to these requirements. We also include the packaging, processconditions etc into the product audit.

Myriam
 
#7
Naturlijk............

Myriam. That's great advice.:agree1:

Use customer issues (complaints and such like) first as a priority and then use internal indicators of past 'caught' problems and after that, new products. Use 'risk' as the main driver. I had no issues over at least two 3rd party audits and a couple of 'corporate' audits. And performance improved too!

Andy
 
M

MONIA

#8
I have question concerning manufacturing audit plan? Szhould it be done like each step of the process once a week. So for example molding, trimming, packing each once a week? Should incoming control and despatch be a part of that? Maybe someone has an example of manufacturing process form (sheet) and plan?
 

xfngrs

Quite Involved in Discussions
#9
Confusion. We are currently being audited and being told that product audits are by nature redundant. That we would maybe take a part out of somewhere on the assembly line and have someone measure it, recording the measurements. You label the part and set it aside and later someone else takes the exact same measurements.

If we add it as a normal measurement to a checklist, it is no longer a product audit as it is a regular thing. It would have to be for a limited time.

Is this everyone else's understanding? I've never heard this before.

:thanx:
 

Stijloor

Staff member
Super Moderator
#10
Confusion. We are currently being audited and being told that product audits are by nature redundant. That we would maybe take a part out of somewhere on the assembly line and have someone measure it, recording the measurements. You label the part and set it aside and later someone else takes the exact same measurements.

If we add it as a normal measurement to a checklist, it is no longer a product audit as it is a regular thing. It would have to be for a limited time.

Is this everyone else's understanding? I've never heard this before.

:thanx:
Yep! The famous "double-check" performed preferably by persons independent from the process. Does not add a lick of value, but the automotive customers have been badly burned quite a few times with nonconforming product including serious labeling issues; hence this requirement. The product audit frequency should depend on the confidence you have in the preceding inspection and test activities.

Stijloor.
 
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