Audit

EXECUTIVE SUMMARY:

RECOMMENDATIONS:

FACILITY

<50% Very Poor - IMMEDIATE Corrective Action Required
51-70% Poor - Corrective Action Required
71-80% Average - Improvement Required
81-90% Good - Improvement Recommended
>91% Very Good - Monitoring Recommended

SAFETY & ENVIRONMENT
WORK ENVIRONMENT

Is the general working environment in a safe & health condition for operators?

NO spilled hazardous materials or liquids?

Combustible scrap, debris & waste stored safely and removed?

Work areas adequately illuminated?

MACHINE GUARDING

Is machinery being operated properly guarded / secured to prevent injuries to operators?

Power shut-off switch within reach of the operator's position?

Foot-operated switches guarded to prevent accidental actuation?

Emergency stop buttons colored red and working?

Moving chains and gears properly guarded?

HAZARDOUS CHEMICAL EXPOSURE

Is the operator not exposed to, or adhering to safe working practices in terms of chemical exposure?

Eye wash fountains and safety showers provided?

All containers, such as vats, storage tanks, etc., labeled?

All staff are using relevant PPE and have clean uniforms. Personal protective clothing and equipment Std?

No eating in the workplace?

OPERATOR SAFETY

Is the operators protected against the necessary safety risks in the work place?

Floor & Wall Openings: floor openings guarded?

Forklifts / Vehicles: warning horn, trained personnel?

Noise: hearing protective equipment?

Spray Machines: adequate ventilation?

Aisles & Passage Ways: aisles and passageways kept clear, marked as appropriate, wet surfaces covered with non-slip materials?

LOCKOUT/TAGOUT

Is all machinery or equipment blocked or locked-out during cleaning, servicing, adjusting or setting up operation, whenever required?

Lock Out Tag available / not accessible?

Safe job procedure established and rigidly followed?

WORK PLACE ORGANIZATION (5S)
SORT / ORGANIZATION

Is the workplace well organized?

Unneeded equipment, tools, furniture, etc. are present?

Unneeded items are on walls, bulletin boards?

Items are present in aisle ways, stairways, corners?

Unneeded inventory, supplies, parts, or materials are present?

Safety hazards ( water, oil, chemicals, machines ) exist?

SET IN ORDER / ORDERLINESS

Are all work areas maintained in a state of order?

Correct places for items are not obvious, Items are not in there correct places?

Aisle ways, workstations, equipment locations are not indicated?

Items are not put away immediately after use?

Height and quantity limits are not obvious?

SHINE / CLEANLINESS

Are all work areas maintained in a state of cleanliness?

Cleaning, and looking for ways to keep it clean and organized?

Floors, walls, stairs, and surfaces are not free of dirt, oil and grease?

Equipment is not kept clean and free of dirt, oil, and grease?

Cleaning materials are not easily accessible?

Lines, labels, signs, etc. are not clean and unbroken?

Other cleaning problems ( of any kind ) are present?

STANDARDIZE / ADHERENCE

Is the necessary work standards, visual aids available, and adhered to?

Maintain the workplace as per standard visual aids?

Necessary information is not available, All standards are not known and visible?

Checklists don't exist for all cleaning and maintenance jobs?

All quantities and limits are not easily recognizable, How many items can't be located in 30 seconds?

PROCESS CONTROL / FPF
DOCUMENTATION / TOOLS

Is the necessary documentation and standards available?

Process / FPF Manual available and up to date?

Visual Aids available and current?

Gauges and Tools available & calibrated?

Forms for FPF Available & Legible?

SETUP / 1ST PIECE APPROVAL

Is the start of shift setup and 1st piece approval carried out?

All Machine Check Points Completed prior to start of 1st run?

All Process & Product Points Completed prior to start of run & Signed?

First Piece Approval part available and stamped correctly.

PROCESS CONTROL

Is the process in control against the set standards, or process parameters?

Process setup as per Process/work order / WI?

Process/work order signed and updated?

SPC Charts updated and actions taken on deviations, FPF Documents updated and signed

PROCESS MONITORING / PERFORMANCE

Is the FPF Performance monitored, at regular intervals?

Process Performance Boards maintained, all required information posted on Boards?

PROCESS VALIDATION

Is the FPF 5P Audit carried out and actioned?)

FPF Audit Checklist completed and current?

FPF Performance Chart updated?

Non conformance communicated and actioned, Escalation of failures (if needed)

CUSTOMER ISSUES & ACTIONS

Are operators aware of customer complaints and is actions taken?

Quality Alert posted and Current?

Customer Reject Samples available?

Actions taken based on corrective actions documented?

STANDARDIZED WORK
WORK STANDARD

Is the work standard available with the necessary information?

Cycle Time?

Machine Layout?

Order of Operations?

Work Sequence for the operator (visual)?

Quality Checks?

Safety Precautions?

Trained operator?

WORK SEQUENCE

Is the operator conducting the work as stipulated in the STD Work instruction?

Work activity / sequence against std instruction?

Devices / Tools / Machinery used correctly?

Continuous Flow of product?

Cycle Time is kept to the standard (check SWI)?

STANDARD WIP

Is there any material WIP, or visible material flow issues?

Imbalanced parts or unfinished work pieces?

Excessive WIP / Material before and after process?

Next process waiting for material?

WASTE MANAGEMENT

Is there any evidence of 7 wastes and action taken to correct?

Transportation (moving products that is not actually required to perform the processing)?

Inventory (all components, work-in-progress and finished product not being processed)?

Motion (people or equipment moving or walking more than is required to perform the processing)?

Waiting (waiting for the next production step)?

Overproduction (production ahead of demand)?

Over Processing (due to poor tool or product design creating activity)?

Defects (the effort involved in inspecting for and fixing defects)?

OPERATIONAL PERFORMANCE

Is the performance tracked, maintained and action taken on deviations?

Performance standards established and known, Downtime sheets, Hourly output sheets, and tracking?

Actual performance in line with targets Internal PPM, FPF%, Productivity?

Close-Out

ACTION DECK

SAFETY & ENVIRONMENT

SHE#

Action

By Whom

By When

5S / WORK PLACE ORGANIZATION

5S#

Action

By Whom

By When

PROCESS CONTROL / FPF

FPF#

Action

By Whom

By When

STANDARDIZED WORK

SWI#

Action

By Whom

By When
SIGNATURES
Auditor / Assessor

Auditee

Signature#
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