Definition Product Audit vs. Dock Audit vs. Layout Audit - Differences

I

Isocyanate

#1
Hi there,

What is the difference between a Product Audit, Dock Audit and Layout Audit.
How often should these be conducted in accordance to the standard? What are the major differences? I have been using an old schedule that combines Product/Dock/Layout.
I have recently discoverd that the layout audit should be done on an annual basis.( Is this like a a requalification?) what charaterristics/physical properties should audited in this?
Are product audits always on Finished Goods??? Does anyone have a format od these audits...???? A lot of questions.. Sorry.

Thanks for your answers

;-)
 
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Stijloor

Staff member
Super Moderator
#2
Re: Different between Product/Dock/Layout Audit

Welcome to The Cove! :agree1: :agree1:

A Product Audit is required by ISO/TS 16949:2002. Look at the requirement and implement it so that it serves your organization. Some organizations use roving inpectors for that purpose. They go from station to station based on a predetermined inspection schedule based on potential risk and criticality of the product.

A Dock Audit can be viewed as a Product Audit as well, but be aware that some Customers have included this in their Customer Specific Requirements (CSR's).

The Layout Inspection requirement is usually contained in the CSR's. Chrysler would be a good example of a Customer that requires this.

Keep in mind that you must study your CSR's to determine the specific inspection and audit requirements. Next, look at ISO/TS and make it work for you.

Stijloor.
 

Howard Atkins

Forum Administrator
Staff member
Admin
#3
Re: Different between Product/Dock/Layout Audit

I have a slightly different view:

Product audits are required by TS as said by Stiljoor
8.2.2.3 Product audit
The organization shall audit products at appropriate stages of production and delivery to verify conformity to all specified requirements, such as product dimensions, functionality, packaging and labelling, at a defined frequency.
As it states here "appropriate stages" I disagree that the dock audit answers this requirement.
The dock audit was a requirement from QS9000 and has been adopted by some to mean the product audit, most dock audits do not audit the part to the same level as required by the clause. I also would say that as invariably the Dock Audit is part of the normal flow of the part as seen on the Flow Chart and Control Plan it is not an audit.
The product audit in my mind is based on the requirements of VDA 6.5, for examples see the following post Product Audit
8.2.4.1 Layout inspection and functional testing
this is not an audit rather
A layout inspection and a functional verification to applicable customer engineering material and performance standards shall be performed for each product as specified in the control plans. Results shall be available for customer review
This can be performed at the companies instigation or as required by the customer.
The use of layout at your own instigation should be as a result of the various risk analyzes that you have performed.
Some customers require an annual layout others do not.
As always read what the standard actually says
 
J

JaneB

#4
Re: Different between Product/Dock/Layout Audit

Guys, that's a new one on me. What is a 'dock' audit?
 

Jim Wynne

Staff member
Admin
#5
Re: Different between Product/Dock/Layout Audit

Guys, that's a new one on me. What is a 'dock' audit?
Inspection of finished goods prior to shipment, sometimes done after the goods have been staged for shipment on the shipping "dock."
 
J

JaneB

#6
Re: Different between Product/Dock/Layout Audit

Inspection of finished goods prior to shipment, sometimes done after the goods have been staged for shipment on the shipping "dock."
Is this the same as/similar to a final inspection before release?
 
M

Matt Swartwood

#7
Re: Different between Product/Dock/Layout Audit

Is this the same as/similar to a final inspection before release?
Yes it's similar. The difference is that with a dock audit, it is a last chance audit to verify customer specific requirements are met. This audit could include dimensional, packaging methods, count accuracy, bar code labeling requirements, etc. We sometimes use dock audits to verify corrective action effectiveness and also as a short term containment plan for corrective action.

Isocyanate, the following would be my definitions of the terms you listed without knowing the application or field that you are in.

Product Audit: In process inspection that inspectors or the operators perform periodically throughout their production run to ensure continued compliance to the print or to meet statistical requirements. The control plan or part specific inspection instructions usually are used to dictate how many pieces to check and at what frequency. This is not 100% dimensional inspection; only a few critical dimensions.

Dock Audit: Sometimes categorized as a product audit, but in a nutshell is a last chance verification to customer specific requirements as described above response to JaneB. Typically, the quantity of parts is dictated by an AQL level or percentage of the total shipment. The frequency of inspection could be each shipment or if on a skip lot plan, could be every 5 or 10 shipments. This is also not 100% dimensional verification (if any at all); only key dimensions.

Layout Audit: Never heard this called an audit, but I am assuming you are talking about the first article inspection. Some call it Initial Sample Inspection Report (ISIR), some call it Pre-Production Approval Process (PPAP), and some call it First Article Inspection (FAI). All of these are typically a 100% inspection on one or more pieces. This data, along with other manufacturing information, material traceability, etc is sent to the customer for approval before production can begin. Some customers require periodic re-verification annually to ensure that your processes are still in check.

Hope this has been of some help to you.
 

Howard Atkins

Forum Administrator
Staff member
Admin
#8
This is one of the occasions where there is a real difference between English and American.
By definition an audit cannot be a routine inspection, cannot be in the normal flow of production otherwise it is not an audit but part of the normal production.
 
R

ralphsulser

#9
Re: Different between Product/Dock/Layout Audit

Layout Audit: Never heard this called an audit, but I am assuming you are talking about the first article inspection. Some call it Initial Sample Inspection Report (ISIR), some call it Pre-Production Approval Process (PPAP), and some call it First Article Inspection (FAI). All of these are typically a 100% inspection on one or more pieces. This data, along with other manufacturing information, material traceability, etc is sent to the customer for approval before production can begin. Some customers require periodic re-verification annually to ensure that your processes are still in check.
Hope this has been of some help to you.
You are correct, the automotive customer specifics for Ford require an annual layout of each part and the report and parts available for review.
We have a monthly schedule to cover all the parts during the year
 

Jim Wynne

Staff member
Admin
#10
Re: Different between Product/Dock/Layout Audit

<snip>
Layout Audit: Never heard this called an audit, but I am assuming you are talking about the first article inspection. Some call it Initial Sample Inspection Report (ISIR), some call it Pre-Production Approval Process (PPAP), and some call it First Article Inspection (FAI).
Just for clarity, "PPAP" stands for Production Part Approval Process, and the term isn't synonymous with layout inspection. PPAP usually includes a layout inspection report, along with a whole lot of other stuff. Also, a layout doesn't necessarily involve a first piece or first article; in the automotive world it's sometimes required on an annual basis, long after the PPAP and initial layout have been approved.
 
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