Roving Audits Checksheets

E

Eloy Gomez

#1
We are an AS9100 Aerospace company, our processes included manufacturing of non-critical flight airplane parts and components.

We have several departments to name a few: Assembly, Paint, Autoclave/Ovens, Layup, Tooling, Machine shop, Material Control..

I was wondering if anyone had a draft checklist to audit a manufacturing area that they could pass along. Or how to create one. Thanks in advance.
 
Elsmar Forum Sponsor
J

JaxQC

#2
To design your audit checklist, look at what the floor checks, say Paint area. Audit that the checks are being done (forms filled out) and also check that the checks are correct ie…paint viscosity is good, filters are changed, gage checks pass, thickness is correct. Do the check yourself or have the operator do it. Verify that the numbers match. You’ll quickly find out that “pencil whipping” disappears. Do the checks intensely at first, you don’t have to do the actual verification checks all the time long term but by doing them at random the operators don’t know when you’re coming but that you will be doing it sometime. Your test results need to match theirs and they will know that they have to do the checks, not just the paperwork.

Also incorporate specific issues. Customer returns, scrap issues, items may change. Be added or dropped as fixes implemented and verified.
 
E

Eloy Gomez

#3
To design your audit checklist, look at what the floor checks, say Paint area. Audit that the checks are being done (forms filled out) and also check that the checks are correct ie…paint viscosity is good, filters are changed, gage checks pass, thickness is correct. Do the check yourself or have the operator do it. Verify that the numbers match. You’ll quickly find out that “pencil whipping” disappears. Do the checks intensely at first, you don’t have to do the actual verification checks all the time long term but by doing them at random the operators don’t know when you’re coming but that you will be doing it sometime. Your test results need to match theirs and they will know that they have to do the checks, not just the paperwork.

Also incorporate specific issues. Customer returns, scrap issues, items may change. Be added or dropped as fixes implemented and verified.
This are great ideas for the paint audit checklist. Thanks!!!!!!!!:agree1:
 

bpritts

Involved - Posts
#4
Here's a generic process audit checklist. One of my clients designed this, with input from our ISO TS 16949 (automotive version of 9001) gap study.

It's pretty straightforward.

Another aspect to consider - if the firm uses "5s" thinking - it's great to audit the workplace to see if everything is where it should be.

Best...........Brad
 

Attachments

D

DrM2u

#6
We are an AS9100 Aerospace company, our processes included manufacturing of non-critical flight airplane parts and components.

We have several departments to name a few: Assembly, Paint, Autoclave/Ovens, Layup, Tooling, Machine shop, Material Control..

I was wondering if anyone had a draft checklist to audit a manufacturing area that they could pass along. Or how to create one. Thanks in advance.
I have previously posted a sample audit sheet document called Process Audit Sheet and a sample of what the audit sheet could evolve to named Improvement Actions. Hope this helps. You can find these filed by searching the Posted File Attachments List in the main page.
 
Last edited by a moderator:
#7
Some of the questions seem overly vanilla and unstraightforward to me, eg:
"Are process linkages established? Are process inputs / outputs clearly
identified?"
I agree, Jane. This type of audit list leaves it open to a whole lot of interpretation. Plus, asking a question like 'Is there opportunity to improve?' is a little naive - it's subjective in many ways and frankly, what process couldn't be improved at some stage. BTW - along with that, how many plants would really take an auditor's comments on improvement seriously, really?

Like all checklists, they need to be developed for the specific environment they're used in....
 
J

JaneB

#8
Like all checklists, they need to be developed for the specific environment they're used in....
Yes - when they are used (and there's a place for checklists but only at times, I think the more specific, the better. So the examples suggested for the Paint Area I think are good. Gives good examples of the kinds of specific questions that a skilled operator/inspector have in mind, & tend to run through almost automatically, and they're good to capture.

Whereas on the other one, something like 'are inputs and outputs defined?'... well, they might be the kind of questions that an auditor or consultant might have in mind or ask themselves, perhaps, but I'd be loathe to see them turn up on a checklist because they're just too broad and vague to be useful.

Sorry if that sounds negative, because I know people posting that kind of thing want to be helpful, but it just highlights the importance of proper auditor selection, training and experience, so they're competent to audit a process. Someone who isn't, armed with that kind of checklist and trying to fill it in, is akin to a 'paint by numbers' type of recipe for disaster in my opinion.
 
D

dknox4

#9
For manufacturing process audits, I have always used the FMEA's and control plans to develop product & process checks for the checklists. I also have the generics for housekeeping/documentation..etc included but I leave the inputs/outputs/effectiveness type stuff for the system audits.
 
Thread starter Similar threads Forum Replies Date
R Roving Audits - Main functions is to audit the manufacturing process General Auditing Discussions 18
lanley liao How to understand this words that the planning of internal audit shall take into consideration the results of previous audits? Oil and Gas Industry Standards and Regulations 10
J External third party audits Registrars and Notified Bodies 1
B How many nonconformances have you received on average during IATF audits? General Auditing Discussions 24
M ISO13485:2016, MDSAP and Internal Audits ISO 13485:2016 - Medical Device Quality Management Systems 8
G 0 non conformities in registrar audits over 4 years Management Review Meetings and related Processes 12
S Would this be a second site for the purposes of internal and third party audits? General Auditing Discussions 4
R Remote Audits for ISO 9001 (or any other standard) General Auditing Discussions 31
J ISMS - Internal Audits Internal Auditing 3
A TUV Audits - 21 CFR 820 General Auditing Discussions 6
L Documented Information in Internal Audits Process (9.2) ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 4
D CB and customer audits considered as internal audits? General Auditing Discussions 9
R IATF 16949 - Outsourcing of internal audits Internal Auditing 10
M Major vs. Minor for Internal Audits? Internal Auditing 10
J ISO 13485 System 'soft start' - How to best reflect this in initial audits, management review minutes and other records? ISO 13485:2016 - Medical Device Quality Management Systems 3
D Layered Process Audits - FCA 9.2.2 - Exemption Clause? IATF 16949 - Automotive Quality Systems Standard 5
S Obligation to accept customer audits? IATF 16949 - Automotive Quality Systems Standard 23
M Supplier Audits - Stop Wasting Everyone's Time! General Auditing Discussions 15
C Internal Audits in a tiny Dx Company Internal Auditing 33
H ISO 13485 - Separate Microbiology Audits ISO 13485:2016 - Medical Device Quality Management Systems 8
A Question on ISO 14001:2015 - Are annual audits required? ISO 14001:2015 Specific Discussions 11
H Remote product audits in Coivd-19 - IATF 16949 9.2.2.4 IATF 16949 - Automotive Quality Systems Standard 3
N Sampling Plan for Internal Audits - ISO 2859 or 3951 - Or Neither? Internal Auditing 6
O ISO13485 implementation - Are internal audits expected before stage 1 audit? Design and Development of Products and Processes 3
Ed Panek Corona Virus impact on Supplier Audits and Received Parts ISO 13485:2016 - Medical Device Quality Management Systems 4
JoCam Increase to bi-annual ISO 13485 audits ISO 13485:2016 - Medical Device Quality Management Systems 2
P Supplier Audits in the wake of COVID-19 ISO 14971 - Medical Device Risk Management 3
O Informational Scaling back internal audits due to corona virus while avoiding a NC Internal Auditing 7
R Is it required to have an SOP for external audits? Medical Device and FDA Regulations and Standards News 7
G Internal Audits and Employee engagement Internal Auditing 16
D Root Cause for Missed Audits Misc. Quality Assurance and Business Systems Related Topics 1
M Notified Body audits -Class Ia medical device product EU Medical Device Regulations 4
S Internal audit discrepancy - We missed a few audits that were scheduled Internal Auditing 12
C Design and implementation of process audits as defined within IATF 16949 IATF 16949 - Automotive Quality Systems Standard 2
F ISO 17025 8.8 Internal Audits in a segmented company ISO 17025 related Discussions 5
J Requirements for Layered Process Audits including Maintenance, Shipping, Receiving IATF 16949 - Automotive Quality Systems Standard 4
qualprod Internal Audits - Categories of non conformances Internal Auditing 12
G Non Conformance During ISO 9001 Audit - Not All Internal Audits Completed General Auditing Discussions 19
K A way to monitor our Internal Audits as a KPI AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 7
blackholequasar Internal Auditing Inspiration - Getting volunteers to perform internal audits. Internal Auditing 22
Sidney Vianna Interesting Discussion ISO 9001 audits from the perspective of registrants' customers - an interesting paper Registrars and Notified Bodies 0
M Honda Audits - Does anyone have any experience with the QAV audit? General Auditing Discussions 3
A External Auditor issue with Internal Audits Internal Auditing 7
W Internal Auditing carried out by a 3rd party - Review of previous audits AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
H IATF 16949 9.2.2.3 - Manufacturing process audits IATF 16949 - Automotive Quality Systems Standard 11
Y Performing product audits in a manufacturing facility Manufacturing and Related Processes 13
Genofear Customer wants to audit our supplier audits - seems inappropriate General Auditing Discussions 11
E Informational Internal Audits - Wear multiple hats what can and can't I audit (so I'm not auditing my own work) Internal Auditing 149
A Supplier Process Audits - Creation of Reports General Auditing Discussions 3
Gman2 Quality Record Retention (Internal Audits, CA's) ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 9

Similar threads

Top Bottom