Shift Audits Proposal

A

andrewg

#1
I need some advice. :frust:

My organisation is currently undergoing some reorganisation with some of our auditing resource being cut. To this end, the following was proposed;

Our current Manufacturing process audits (which cover both day shift and Night shift) to be replaced by an audit in either day or back shift. The night shift would not be covered.

I expressed concearn about covering all shifts and my manager has suggested a limited audit in cluster of areas on a much reduced frequency.

So in essence, our nightshift coverage would go from 20 per year to 4 audits per year. Each area would have much less time spent in them. I am not comfortable with this.

Does anybody have any views????
 
Elsmar Forum Sponsor
C

Craig H.

#2
Do your shift personnel rotate? That is, do they change shifts, or do the same people work each shift all of the time?
 
A

andrewg

#3
Yes - the shift staff do rotate on a weekly basis. My understanding is that the shift element of Auditing is meant to test that the linkages and interactions with other processes are the same from shift to shift.
 

Stijloor

Staff member
Super Moderator
#4
Yes - the shift staff do rotate on a weekly basis. My understanding is that the shift element of Auditing is meant to test that the linkages and interactions with other processes are the same from shift to shift.
And that the processes are performed in a similar manner on all shifts.

There is also a requirement in ISO/TS where "all shifts" is mentioned.
Look at Clause 5.5.1.1 "Responsibility for quality."

Stijloor.
 
#5
I need some advice. :frust:

My organisation is currently undergoing some reorganisation with some of our auditing resource being cut. To this end, the following was proposed;

Our current Manufacturing process audits (which cover both day shift and Night shift) to be replaced by an audit in either day or back shift. The night shift would not be covered.

I expressed concearn about covering all shifts and my manager has suggested a limited audit in cluster of areas on a much reduced frequency.

So in essence, our nightshift coverage would go from 20 per year to 4 audits per year. Each area would have much less time spent in them. I am not comfortable with this.

Does anybody have any views????
Andrew:

I'm not sure you can 'get away with' dropping the night shift. I'd need to know a bit more about what they do etc. As Jan says, the principle is that all shifts do the same things.

I'd be interested to know why you were doing 20 audits a year. How many manufacturing processes have you got? Also, you might want to look at the planning criteria anyways. Cutting back on audit resources can indicate your management don't see a benefit from them and, likewise, unless you have a good plan - based on status and importance - you may be feeding this problem. If you are cutting back - apparently abitrarily - from 20 to 4 you may be in trouble for other reasons.
 
C

Craig H.

#6
And that the processes are performed in a similar manner on all shifts.

There is also a requirement in ISO/TS where "all shifts" is mentioned.
Look at Clause 5.5.1.1 "Responsibility for quality."

Stijloor.
Bur if all shifts perform the same tasks, in this case auditing one shift during the day once each week for four weeks would cover all shifts, wouldn't it?
 

Stijloor

Staff member
Super Moderator
#7
But if all shifts perform the same tasks, in this case auditing one shift during the day once each week for four weeks would cover all shifts, wouldn't it?
Craig, do you mean if these folks work on rotating shifts?

For example, I have a Client for which I perform internal audits.
They have an A, B, C, and D shift. They work on a rotating basis.
I make sure when scheduling the audits that all A-B-C-D shfts are "visited" and audited.

Stijloor.
 

Howard Atkins

Forum Administrator
Staff member
Admin
#8
I need some advice. :frust:

My organisation is currently undergoing some reorganisation with some of our auditing resource being cut. To this end, the following was proposed;

Our current Manufacturing process audits (which cover both day shift and Night shift) to be replaced by an audit in either day or back shift. The night shift would not be covered.

I expressed concearn about covering all shifts and my manager has suggested a limited audit in cluster of areas on a much reduced frequency.

So in essence, our nightshift coverage would go from 20 per year to 4 audits per year. Each area would have much less time spent in them. I am not comfortable with this.

Does anybody have any views????
Please can you confirm that you are talking about ISO/TS
20 audits a year seems to be a lot, what is in this audit?
Thanks
 
#9
As was pointed out earlier, the 'off shifts' do not always have the same level of support that the 1st shift has - the other processes etc. are often not resourced. So, it's not a case of the same people being audited, during the daytime and that being a fair represntation of when they're working the off shift, IMHO.

You'd have to be there actually during the off shifts to see how they deal with things when the (reduced) support is too........
 
A

andrewg

#10
A know 20 audits a year sounds alot however let me explain......

My organisations business is semiconductor silicon wafers. Our wafer process number some 17 different processes. Additional audits have been scheduled in areas where issues have been identified (based on previous audit results and customer concearns). Knowing my process, I do not consider 20 audits per year to be excessive.

During our third party assessment, our audit programme has always been seen as a good solid example of an active robust and effective audit system.

Resources are being cut by senior management who have no QA background, no qualification in TS nor ISO9001. My issue is that the Management making the decision do so by purely looking at manpower numbers and clearly are not seeing the benefit from our audit programme. My concearn is that by going down this road, my organisation will leave itself open for a concearn being raised during our third party assessment.

I know it is my position therfore to explain the needs of auditing to Senior Management, however in this case, they seem unwilling to listen or even consider. All that is seen is the bottom line on the balance sheet !!
 
Thread starter Similar threads Forum Replies Date
N New (Upgraded Technology) vs Existing Equipment - Measurements Shift Design and Development of Products and Processes 4
M FDA Considers Shift on Medical Device Quality System Regulations - 2018 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 0
R Defect Display Area for Employee Shift Change Information Misc. Quality Assurance and Business Systems Related Topics 1
C How to handle this Inspection conflict? Second Shift Inspector? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 8
C Positional Tolerance - Bonus / Datum Shift / ASME Y14.5M - Clarification Various Other Specifications, Standards, and related Requirements 9
P Please share a 'Shift to Shift' Quality Report Template Document Control Systems, Procedures, Forms and Templates 3
P Rolls-Royce SABRe2 - Shift Handover Procedure Customer and Company Specific Requirements 2
N Workin' The Night Shift... ~*yawn*~ Coffee Break and Water Cooler Discussions 5
N 1st Shift vs. 2nd Shift Production Crews - How to end this war? Career and Occupation Discussions 15
M Significant FDA Medical Device Marketing Shift... 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 10
optomist1 Maximum Shift Tolerance Restrained Part - Calculation of Datum Shifts Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
G Assessing Process Capability on Variation (Hardware Adjustment Mean Shift) Capability, Accuracy and Stability - Processes, Machines, etc. 4
R GM's Shift Change Over C.A.R.E Area Information Wanted APQP and PPAP 1
P Floor Supervisor End of Shift Report ideas and/or template wanted Manufacturing and Related Processes 7
S Monitoring is 1/shift. Is this the minimum required? CQI-11 Expert needed. IATF 16949 - Automotive Quality Systems Standard 3
somashekar Wavelength Shift in Emitter Assemblies - Causes Manufacturing and Related Processes 1
R Sigma Level and the theoretical Six Sigma Shift Six Sigma 5
A What are you thoughts on the 1.5 sigma shift Six Sigma 3
Jim Wynne George Box and the 1.5-Sigma Shift Imported Legacy Blogs 6
N Supplier Scorecards - 1.5 Sigma shift? Supplier Quality Assurance and other Supplier Issues 12
P Does Six Sigma Project have to Reduce Variability? What about a mean shift to target? Six Sigma 6
P Lack of 3rd Shift Internal Audit - Major or Minor NC (Nonconformance)? Internal Auditing 17
T Monitoring a shift of the average in an SPC chart Statistical Analysis Tools, Techniques and SPC 11
M TUV NCR 1 - Internal Audit did not audit the second shift Internal Auditing 26
Jim Wynne Paradigm Shift in QA? Another View Philosophy, Gurus, Innovation and Evolution 23
Marc Is the quality profession about to become obsolete? Paradigm Shift Philosophy, Gurus, Innovation and Evolution 19
B Not Full (Partial) Lot at End of the Shift - Sample Size AQL - Acceptable Quality Level 4
M 100% Measurement Shift to Sample Inspection? PCB Substrates Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
D Is there a process shift and/or trend in the attached control chart? Statistical Analysis Tools, Techniques and SPC 33
P TS 16949 Internal Audit Requirements - What to cover in each shift? Internal Auditing 13
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

Similar threads

Top Bottom