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

R

ralphsulser

#11
Here is a latest list of items we have to supply for PPAP to be accepted. I replaced our company name with "OUR":
FORD
Ref.:Global Phased PPAP Requirements Handbook Appendix D

TABLE OF CONTENTS

PPAP Requirements-Functional checklist

TAB ITEM # Requirement
A 1 Design Record FORD DRAWING
B 2 Engineering Change Documents N/A NO SREA or ALERTS REQUIRED
C 3 Customer Engineering Approval FORD DVP & R, ESER, PTF-024 Characteristic classification Transmittal (Pass thru characteristics)
D 4 Design FMEA FORD DFMEA
E 5 Process Flow Diagrams OUR FLOW DIAGRAM
F 6 Process FMEA OUR PFMEA
G 7 Control Plan OUR CONTROL PLAN
H 8 Measure System Analysis Studies OUR (Gage R&R)
I 9 Dimensional Results OUR LAYOUT-Bubble print, dimensional results report & 2 samples marked 1 and 2
J 10 Records of Material/ OUR METALLURGICAL
Performance Test Results DATA & STEEL
CHEMICAL ANALYSIS REPORT, CQI-9, and WHTX audit report
K 11 Initial Process Studies OUR CAPABILITY STUDY
L 12 Qualified Laboratory Documentation N/A NO OUTSIDE LAB
M 13 Appearance Approval Reports N/A NON APPEARANCE ITEM
N 14 Sample Production Parts OUR SUPPLIED TO PRODUCT
ENGINEERING
O 15 Master Sample OUR RETAINS
P 16 Checking Aids MSC LISTS
Q 17 Customer Specific Requirements FORD SPECIFIC-Trademark requirement/Exemption, Capacity report
R 18 PPAP/PSW Warrant OUR SUPPLIED
S 19 Bulk Material expectations NOT APPLICABLE
T 20 ELV Reporting IMDS System
U 21 AIAG Bar-Coded shipping label OUR SUPPLIED
V 22 Packing Method-Dunnage OUR SUPPLIED
W 23 ISO/TS 16949:2002 Certification OUR SUPPLIED-AQA INTL.
X 24 ISO 14001:2004 Certficate OUR SUPPLIED-ORION
 
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M

Matt Swartwood

#12
Very similar to what we submit to the trucking industry. I stand corrected on the acronym PPAP. I knew that.. not sure what I was thinking LOL :confused:
 
D

dianel

#13
I audit the items on my control plans or only items that i have seen nonconformities/customer complaints in the past. Otherwise, what is the use? I dont believe in a dock audit. If processes are in control and stable upstream you wont need a dock audit. In addition, if processes are not in control and stable your audit /containment should be done upstream so the least amount of "rework" or damage is done. As far as i am concerned, once something gets to the dock it is too late to be prevented, costs too much, and goes against the entire concept of ISO itself.
 
H

HONEST_123

#14
Re: Different between Product/Dock/Layout Audit

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.
 

Stijloor

Staff member
Super Moderator
#15
Re: Different between Product/Dock/Layout Audit

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.
Look at Post #3 in this thread (from our Fellow Cover Howard Atkins) for an explananation of "Layout Inspection."

Stijloor.
 

Jim Wynne

Staff member
Admin
#16
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.
See my earlier post in this thread.
 

John Broomfield

Staff member
Super Moderator
#17
Re: Different between Product/Dock/Layout Audit

Is this the same as/similar to a final inspection before release?
A dock audit is for someone independent to experience what the customer experiences on unpacking the product ready for use.

As you can imagine, it can be expensive, disruptive and very valuable so it must be carefully planned and taken very seriously. It could be part of design validation.

It is obviously not done on music CDs!

BTW, this activity has to be independent to be called audit, otherwise it is monitoring, measurement, inspection, testing or management.
 
A

Abdul Majid

#18
Re: Different between Product/Dock/Layout Audit

Final Inspection id seperate from dock audit,
dock audit includes the packaging condition , material as per invoice.etc.
 
R

rshollack

#19
Dock Audit sometimes is incoming inspection or EOL inspection to verify product is ready for shipment.

Product audits are random. The auditor verifies all requirements are followed. An operator may perform a First off inspection and the auditor will verify the inspections have been completed. On a product audit, the auditor may verify a dimensional reading. The audit verifies that actual inspection has taken place and requirements have not been 'pencil whipped' by the operator.
 
#20
Dock Audit sometimes is incoming inspection or EOL inspection to verify product is ready for shipment.

Product audits are random. The auditor verifies all requirements are followed. An operator may perform a First off inspection and the auditor will verify the inspections have been completed. On a product audit, the auditor may verify a dimensional reading. The audit verifies that actual inspection has taken place and requirements have not been 'pencil whipped' by the operator.
Welcome to the Cove! Perhaps you can throw some light on your experience of doing these audits. Others may have a different idea about when and where to do these audits - which may conflict with your comments - so, some further background on your knowledge of doing audits would help greatly.
 
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