Information
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Audit reference number (automatic)
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Description of area/cell/process being audited
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Site and Department
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Scope of the audit (See audit plan and add to this as necessary)
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Conducted by
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Conducted on
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Are there actions which require close out?
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Revisit date (if there are actions to close out)
General Help
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Take photographs or sketch to help clarify any issues you identify as required in each section. Don't forget to record the good points as well.
You must select compliance level from the options:
OK = Satisfactory (It is working effectively and reliably)
NCR = Non-Conforming (It is NOT working effectively)
OBS = Observation (there may be a slight deviation but generally is working well)
OFI = Opportunity for Improvement (ideas that could make it better than it is)
N/A = Not Applicable (this question does not apply to the area being audited) -
Please ensure you write down, or photograph: serial numbers, reference numbers, order numbers etc to ensure that the audit is repeatable
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In order to allow typing information against a question, tap on the text of the question to open the text input box
People Issues
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OK = Satisfactory (It is working effectively and reliably)
NCR = Non-Conforming (It is NOT working effectively)
OBS = Observation (there may be a slight deviation but generally is working well)
OFI = Opportunity for Improvement (ideas that could make it better than it is)
N/A = Not Applicable (this question does not apply to the area being audited
1. People issues (communication)
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Guidance:
Look for evidence of: team talks, noticeboards, (check information is up to date and relevant), KPI graphs, departmental performance figures, information regarding the performance of the quality management system, environmental management system, or health and safety management system (such as accidents, scrap, complaints, OTIF, etc) -
Is there evidence of communication within the department? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
2. People Issues (competence and capability)
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Guidance:
Look for examples of Young persons (Under 18 years of age) and pregnant workers (health and safety concerns). These two groups are especially at risk. Young persons because of inexperience and immaturity and pregnancy can affect ability to carry out certain tasks safely (for example manual handling)
Look for evidence of employees having undergone induction training, quality, environmental and health and safety awareness training, and training for the specific tasks they are performing.
Look especially for tasks which require specific skills or qualification such as driving fork lift trucks, pallet trucks, computer use, changing grinding wheels, measuring or testing product etc.
Competency can be based on education, training, skills, and/or experience. Look for evidence of records of training - are they suitable and sufficient? Are there issues with understanding (for example language barriers). Is there evidence of stress or violent behaviour? is there evidence of unsafe or environmentally unsound behaviour or practice?
Are any of the workers disabled or otherwise disadvantaged in performing the task(s)?
Is there evidence of lack of competence or capability affecting product quality or customer service? Is there evidence of ongoing performance appraisal on persons within the department or area being audited?
Is there adequate supervision? -
Are personnel performing work which could impact on the customer, service, health and safety, or the environment, competent and capable?
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
3. People Issues (responsibility and authority)
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Guidance:
Is it clear what each person's responsibility and authority level is? (Is there evidence of decisions not being made or tasks not been done, because no one is quite sure whose job it is?).
Are the roles clearly defined and documented within a job profile, and if not, how are people informed about their responsibilities and authority levels? responsibilities clear? For example look for authority limits on inventory adjustments unfreezing stock etc. -
Is responsibility and authority clearly defined?
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
Material Issues
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OK = Satisfactory (It is working effectively and reliably)
NCR = Non-Conforming (It is NOT working effectively)
OBS = Observation (there may be a slight deviation but generally is working well)
OFI = Opportunity for Improvement (ideas that could make it better than it is)
N/A = Not Applicable (this question does not apply to the area being audited
1. Materials (Hazards)
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Guidance:
Look for Toxic, Irritant, Sensitising, Corrosive or Carcinogenic chemicals that are in use (including the use of local exhaust ventilation). Check that chemicals are properly labelled (or otherwise identified so it is clear what the contents are and what the corresponding hazards are)
Check that they are listed in the COSHH register, and are used in a safe manner (using the PPE that is recommended).
Check for signs of use of water which might be stale or contain bacteria (such as cooling water) and for signs of water spray in air (Legionella risk)
Look for environmental hazards also, for example use of oils, chemicals hazardous to aquatic life and materials that can cause dust or fume with the resultant risk of explosion, fire or problems with inhalation. -
Are all chemicals in use on the COSHH register and suitably identified controlled to minimise H&S or Environmetal issues? Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
2. Materials (Safe Storage)
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Guidance:
Check all material(s) storage. Is it safe (not exceeding safe working loads for shelving, and safely and suitably stacked - for example stability and load distribution, (especially stability of items on the top shelf to limit the risk of items falling off and hitting someone)
Is storage free from spills and leaks (for example granules on the floor)?
Is it secondary contained as needed?
Is packing in good condition (damaged boxes etc)?
Is storage such that it prevents damage or deterioration to the items concerned?
Does the material in use have a limited shelf life such that it could deteriorate and not function properly (for example seals/gaskets, cement etc) ? How are such materials managed? (stock rotation example, order phasing etc) -
Are all materials stored in a safe manner? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
Equipment issues
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OK = Satisfactory (It is working effectively and reliably)
NCR = Non-Conforming (It is NOT working effectively)
OBS = Observation (there may be a slight deviation but generally is working well)
OFI = Opportunity for Improvement (ideas that could make it better than it is)
N/A = Not Applicable (this question does not apply to the area being audited
1. Equipment (Accuracy and capability)
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Guidance:
Is software, used for assessing planning requirements, validated for accuracy prior to use (for example excel spreadsheets with formulas, forecast information, MRP master data) -
Is equipment and machinery in use; suitable, calibrated and capable? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
2. Equipment (Safety and effectiveness)
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Guidance:
Is equipment in use, in good condition (no exposed wires, broken casings, accessibility to dangerous parts through broken or damaged guards etc).
Is Portable equipment PAT testing as required?
Are items such as shelving, storage (such as filing cabinets), seating, desks in good condition and safe (for example can more than one drawer of a filing cabinet be opened at one time). -
Is equipment and machinery in use safe? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
3. Equipment (Training and authorisation)
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Guidance:
Are personnel using equipment suitably trained or authorised to use such equipment - Check personnel are capable of using things like test and measuring equipment correctly (eg goods inwards checks)
Do records demonstrate that personal have been trained to operate the process or equipment for the reasons of quality, environmental implications and health and safety implications (e.g. using a pallet truck) -
Is all equipment and machinery used by suitably trained and authorised personnel? Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
Environment issues
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OK = Satisfactory (It is working effectively and reliably)
NCR = Non-Conforming (It is NOT working effectively)
OBS = Observation (there may be a slight deviation but generally is working well)
OFI = Opportunity for Improvement (ideas that could make it better than it is)
N/A = Not Applicable (this question does not apply to the area being audited
1. Environment (Infrastructure of the building and environmental conditions)
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Guidance:
Is there evidence of unsafe structural elements of the building (e.g. walls, doors, windows, floor etc)? For example, is the floor level and free from damage, obstruction, or slip/trip hazards.
Are the walls/windows/doorframes, secure and free from elements which could fall off or fail to operate?
Look for areas which could potentially be asbestos, look at the condition. If in doubt, refer to the asbestos survey information. Typically asbestos can be used to lag pipework, or cover pipework but it can also be used for the fabric of the building.
If you believe there is asbestos in the vicinity which potentially is damaged, you should immediately report this to the maintenance supervisor.
Is the temperature, humidity, or other environmental conditions suitable -
Are there issues with the building infrastructure or environmental conditions? Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
2. Environment (access and egress and ergonomics)
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Guidance:
Is there free access and egress to the area being audited? Are fire exits clear? Are there constraints to carrying out tasks due to space or ergonomics of the process? -
Is there sufficient access and egress to the work areas? Are there issues with the ergonomics in the work area?(Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
3. Environment (waste, energy and emissions)
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Guidance:
Are wastes from the process properly segregated and managed? Are recyclable wastes (cardboard, plastics, metal etc) and hazardous wastes (oil contaminated) for example, disposed of in the correct containers?
Are personnel clear on the correct disposal points?
Is equipment turned off when not in use?
Is there any evidence of emissions during the process? -
Are wastes, energy, and emissions properly managed? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
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Verified by
4. Environment (Storage/racking)
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Guidance:
Is storage and racking suitable for the load and safe? (Check racking is marked clearly with the safe working load, is secure so it cannot topple over, and it is properly loaded) ?
Ensure that heavy and light items are distributed such that the risks of manual handling are minimised and the stability of the storage is maintained
Are legs of racking protected from damage?
Ensure that storage is properly stacked/located (i.e. Items are not likely to fall off shelves)
Check for unsuitable storage – for example wooden pallets used to support a load greater than their capacity or condition warrants. -
Is storage/racking suitably managed? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
5. Environment (Fire Hazard)
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Guidance:
Is there any fire hazard in the area (for example: flammable chemicals in use, cardboard/wood or other flammable materials stored in such a way that they may cause of fire - such as against a hot surface)?
Is there any source of ignition in the area (such as welding, brazing or heaters)?
Is the evidence of blocked cooling systems or ventilation on equipment?
Has a fire risk assessment been conducted in the area/department? -
Is there any risk of fire? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
Process Issues
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OK = Satisfactory (It is working effectively and reliably)
NCR = Non-Conforming (It is NOT working effectively)
OBS = Observation (there may be a slight deviation but generally is working well)
OFI = Opportunity for Improvement (ideas that could make it better than it is)
N/A = Not Applicable (this question does not apply to the area being audited
1. Process (change management)
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Guidance:
If there is change in the department, is the integrity of department procedures/processes maintained?
Look for tasks not been carried out because someone is no longer in the department, changes in priority because of change of leadership or responsibility, or new manufacturing processes/departmental processing being implemented with associated learning curves.
For example how are bills of materials, items and routes controlled when changes are made or new products are introduced -
Have there been any changes in the department/area being audited, and what impact has it had?(Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
2. Process (Monitoring measurement of product)
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Guidance:
Relating to the goods receipt element of purchase planning:
Are quality objectives and quality requirements defined for the product (for example quality plans, specifications, work instructions, quality alerts etc).
Are the required verification, validation, monitoring, measurement, inspection and test activities specific to the product carried out correctly? (This could also include visual checks, counts, confirmation of correct product on receipt etc)
Are there suitable records of such inspections and tests?
Is the person responsible for the checks clearly identified?
Are the results of measurements and tests suitably analysed looking for trends, and possibly indicating need for increased or decreased levels of activity? -
Are all relevant checks and measurements being undertaken and suitably analysed?(Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
3. Process (Legal/standards compliance)
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Guidance:
Is the legislation/standard/specification to which the process must comply known, documented and available?
Is the legislation (if applicable) recorded within the legal register?
Consider items such as import/export documentation, country of origin certification, wooden pallet marking related to treatment etc, transport requirements from site1 to warehouse and importing consumable items such wire etc and also how are these items quantified for the purposes of packaging waste directive and Valpak submission -
Are applicable legislation or standards/specifications known? Are they available? Are they complied with?(Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
4. Process (documentation)
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Guidance:
Is the process suitably documented via a process flow chart, work instruction, standard operation, specification sheet, quality, environmental or health and safety alert, booklet etc
If not documented, is the person performing the process suitably trained and/or experienced or supervised/monitored)?
Who is the customer and supplier to the department/process being audited how do we ensure that the requirements of the customer are satisfied? For example sales may be the customer of the planning function, but external suppliers and production are their suppliers.
Are all documents controlled in such a way that changes are identified, the document having an issue/revision number and date, and is it approved prior to issue?
Are documents legible and identifiable?
Are documents of external origin (such as customer drawings/specifications) suitably controlled? (for example drawing from Innoge). -
Is the process suitably documented and is the input/output clearly defined? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
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Verified by
5. Process (measurement)
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Guidance:
What are the key process measures?
Are these displayed? (For example KPI's, departmental charts or graphs etc)? If so, is there improvement noted? if not what actions of being taken to improve things?
Is data generated and analysed looking for trends and the need for action to improve (for example number purchase non-conformities, consumables being out of stock when needed, items not being available for customers when needed, accuracy and correctness of stock and bill of materials, routes, item master data, etc) -
Are key processes measured, analysed, communicated and do they demonstrate appropriate improvement? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
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Verified by
6. Process (Risk assessment/aspects evaluation)
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Guidance:
Are processes being undertaken risk assessed? (Examples of risk assessment are: general, task specific, manual handling, COSHH, PUWER, VDU, explosive atmosphere, young or pregnant workers, noise, fire etc (see section c23 in the health and safety management system)
Are there any outstanding actions from any such assessments?
Are the processes being undertaken covered by the environmental aspect evaluation? (See EM-01 – and the environmental aspects evaluation database - in the environmental management system) -
Are there suitable risk assessments? And are activities covered in environmental aspect evaluation? Are actions from such assessments dealt with? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
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Verified by
7. Process (Data and records)
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Guidance:
Are all data and records, created as part of the process, suitably controlled? (Identified, backed up and suitably stored, with clearly documented disposal and retention periods)
The control of records should include electronic records as well as paper records.
Identify the records within the audit, and ensure that they are covered within the QMS/EMS and H&S management systems
Such records may consist of purchase orders raised, inventory checks, works orders raised, bookings against works orders etc -
Are all data records suitably controlled? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
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Has action been taken to address the action, and to a satisfactory level?
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Verified by
8. Process (Non-conformance/rework/corrective/preventive action)
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Guidance:
When the process goes wrong - and results in nonconformance - is action taken to resolve the issue in terms of documenting the problem, disposal action being taken (scrap, rework etc), containment action (making sure the customers not receive the problem), root cause analysis, and finally corrective action to resolve the root cause? (For example non availability of parts, errors the item data etc)
Additionally, is such failure analysed and improved upon, as well as applying preventive measures proactively?
Is rework being managed effectively? e.g: is the fallout from checking products notified to the planning function? Eg 100% x-raying such that inventory can be adjusted, and works order bookings corrected.
How is the stock managed to ensure that nonconforming items do not show for the purposes of planning? Also how these items returned and managed to ensure they are replaced (process for dispatch and redelivery corrected item) -
Is there a robust process for dealing with non- conformance in the area being audited? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
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Verified by
9. Process (Identification and traceability)
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Guidance:
During the process, is the status of the output of the process (whether it be product or documentation), clear?
How is material managed for traceability purposes (specific silos for specific batches for example)?
How is rework traced in terms of labour costs and for the purposes of traceability? e.g losses against a works order, booking changes etc
How are items that are converted from one item to another managed ? For example SDR 11 product to SDR 17, kits, machining - how is traceability maintained for these items? -
Are all products and items clearly identified and traceable? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
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Verified by
10. Process (PPE - Personal protective equipment)
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Guidance:
Are all personnel wearing PPE which is required for the process (take note of signs and process requirements to identify whether people should be wearing hearing protection eye protection etc)?
Are people suitably trained and made aware of how to use the PPE? IS PPE suitable for its intended purpose (for example a dust mask being used for solvent use, cotton gloves for oil etc)? -
Is a PPE being worn when required? Is it suitable and being correctly used? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
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Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
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Verified by
11. Process (unsafe acts/conditions and accidents)
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Guidance:
Have there been any health and safety, environmental, or quality concerns raised in the area in the last six months? Have there been any accidents in the area in the last six months?
Are there any outstanding actions from surveys and audits from external bodies (such as Owen David, SGS BSi, etc)?
If so, has action been taken to resolve the problems?
Has there been any notification to the HSE of any dangerous occurrence? -
Have there been accidents or near misses related to the process? If so what action(s) have been taken?(Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
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Verified by
12. Process (Emergency)
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Guidance:
Is there evidence of emergency preparedness - spill kits, fire extinguishers, fire exits etc
Do employees (and visitors) have knowledge of emergency plan, knowledge of what to do in the event of a fire, spill, accident etc?
Is all emergency equipment in operational condition (e.g. spill kits full, spill mats available, bunds not full of water, fire extinguishers not discharged etc)? -
Is there suitable emergency preparedness?(Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
-
Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
-
Verified by
13. Process (Outsourcing)
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Guidance:
Are any processes or parts of processes outsourced? If so how are these controlled to ensure compliance to customer requirements, environmental compliance, health and safety compliance, etc)?
If these outsourced activities are carried out on our premises, is the contractor managed through permits to work etc (See C05).
How do we ensure that contractors working on our premises comply with environmental requirements (such a waste, discharges, emissions etc), or health and safety requirements (such as PUWER, working at height etc).
How do we confirm the quality of the outsourced operation?
How is the outsourced activity approved and controlled? -
Is anything outsourced? if so how is it controlled? (Describe/photograph)
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
-
Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
-
Verified by
Specific department or process questions
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OK = Satisfactory (It is working effectively and reliably)
NCR = Non-Conforming (It is NOT working effectively)
OBS = Observation (there may be a slight deviation but generally is working well)
OFI = Opportunity for Improvement (ideas that could make it better than it is)
N/A = Not Applicable (this question does not apply to the area being audited
Process specific questions based on the process flows and ISO requirements
1. Forecast
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Guidance:
How are forecasted sales requirements communicated to the planning department for the purposes of purchase and manufacture?
How is demand consumed from this forecast?
How are large, unexpected, orders consumed? Are these considered to be early demand or additional demand? -
Is demand forecast known and managed?
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
-
Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
-
Verified by
2. Perpetual inventory information
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Guidance:
How do we ensure that there errors in the inventory from PI checks are taken into account for planning purposes?
Stock errors could result in planned orders having to be moved or quantities changed etc - how are sales informed?
How does stock get adjusted and who is authorised to do so? -
Are inventory errors and resulting order changes correctly managed?
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
-
Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
-
Verified by
3. Bill of material (BOM) components
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Guidance:
How are changes to the bill of materials managed from a planning perspective?
How do we prevent the incorrect item being backflushed if we make changes to the bill of materials?
How do we correct errors in backflushing if the wrong BOM item has been backflushed?
How do we manage returns to stores (or not) of BOM items - what if additional items are consumed? -
Are BOM items correctly managed?
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
-
Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
-
Verified by
4. Frozen stock
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Guidance:
How is frozen stock managed?
Who can unfreeze and who sets freeze flag?
How are unique batches of frozen stock managed on the system? (From a planning and stock perspective)
If there are two batches for example, how do we freeze one batch only?
Is it unfreeze verified with quality? -
Is frozen stock properly managed and authorised?
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
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Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
-
Verified by
5. Works order processing
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Guidance:
How are works orders processed in terms of status - from planned through to active?
Is stock of consumables checked prior to order release? (Trial kitting)
How are trials managed?
How are rework orders processed and managed? (For example converting one product to another building kits etc)
How are orders managed where the BOM and ROUTE have changed, or where there are alternatives (such as alternate routes fabricated or moulded, alternative parts can be used etc)
How are such changes notified to all that need to be aware? (such as production, quality, stores etc) -
Are product quantities and bookings correct?
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
-
Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
-
Verified by
5. Production bookings
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Guidance:
How is the count produced fed back into the ERP system? (especially for those items where there is no MES system such as elbow jointing)
How is labour and machine time fed back into the ERP system? (route consumption)
How are items returned from the warehouse and subsequently checked (with resultant scrap) fed back to the works order? And how is the labour for this activity captured? -
Are product quantities and bookings correct?
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
-
Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
-
Verified by
Additional checks
Additional Checklist items
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Additional Check
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Details of additional check
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Compliant?
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Action(s) required:
you must also identify who is responsible for the action(s)
Action(s)
-
Action
-
Responsibility:
-
Has action been taken to address the action, and to a satisfactory level?
-
Verified by
