Layered Process Audit - SafetyCulture Format - Rev 2 - duplicate

• Plant

• Manufacturing Process

• Work Centre

• Part Number

• Prepared by

• Auditor-Enter First Name/Last Name of person completing the audit

• Audit Participant(s)

• Type of Audit (Manager or Supervisor)

  Manager

  Supervisor

• Conducted on

  Date

People

• Has the operator been trained to requirements of the job and is the versatility training matrix updated?

  Yes

  No

• Does it include temp & contract personnel?

  Yes

  No

  N/A

• Are all personnel using all the posted Personal Protective Equipment?

  Yes

  No

  N/A

Standardization / Built in Quality

• Has there been a recent customer incident?

  Yes

  No

• Is the quality alert posted?

  Yes

  No

• Are people trained on the alert & has it been signed off?

  Yes

  No

• Is the work being performed to the instructions on the alert?

  Yes

  No

• Are the employees aware that this is a customer concern & can explain what it is?

  Yes

  No

• Are all quality checks being performed to the inspection sheet requirements as defined by the first off & process checks?

  Yes

  No

  N/A

• Are all the inspection points within the requirements?

  Yes

  No

• Is there a verification station at the work station where there are any of the following happening: final inspection / GP12 / quality gate, (can be temporary or permanent) or where processes have been bypassed.

  Yes

  No

• Is there evidence of standardized work instructions (combination table, standardized work chart, and job element sheets) available at the verification station(s) for the work being done?

  Yes

  No

• Are they being followed & is training matrix is posted & up to date?

  Yes

  No

• Do the trend charts on the I-Charts show an improvement on the top 3 items?

  Yes

  No

• Are the alarm limits for visual defects posted & mentioned in the standardized work instructions?

  Yes

  No

• Are the operators aware of what the alarm limits are?

  Yes

  No

• Is there evidence that verification station(s) are used following significant physical damage to equipment when recovery took longer than 24 hours and the quality of the final product was compromised?

  Yes

  No

• Are the work instructions (JES) for the parts being produced at the station?

  Yes

  No

• Are they being followed? Observe 3 cycles

  Yes

  No

• Are the operators aware of the location of the work instructions?

  Yes

  No

  N/A

• Has the first off process been completed & is the first off tag been completed & posted as per the first-off procedure?

  Yes

  No

  N/A

• Has the safety check sheet been verified?

  Yes

  No

  N/A

• Can the operator show you how they do the checks?

  Yes

  No

• For error proofing/error detection device verification, are master/boundary samples (red rabbit) available for each customer attachment point?

  Yes

  No

  N/A

• Are results recorded? Check data back 1 month

  Yes

  No

• Do the numbers on the boundary samples match what is on the boundary sample sheet

  Yes

  No

• Are process settings and/or parameters being monitored? Choose N/A if there is no equipment/parameters to monitor at the line

  Yes

  No

  N/A

• Are the parameters settings in specification?

  Yes

  No

• Is there any screwdriving equipment at the line

  Yes

  N/A

• Are we monitoring the torque?

  Yes

  No

• Is the calibration sticker up to date?

  Yes

  No

• Is the screw torque with in spec-parameters are on first off?

  Yes

  No

• Are key severity items being controlled? - High Severity items

  Yes

  No

  N/A

• Are customer interface characteristics documented on a special product matrix & displayed?

  Yes

  No

• Are scrap racks/bins/lock boxes present & parts clearly marked & defective parts marked on the scrap sheets?

  Yes

  No

  N/A

• Are the parts clearly marked?

  Yes

  No

• Are the defective parts recorded on scrap sheets or electronically?

  Yes

  No

• Per Inspection sheet / Control Plan, is gauge available & does have proper calibration stickers? Select N/A if there is no gauge at the line

  Yes

  No

  N/A

• Enter fixture/gauge # here

• Is there lot traceability on the parts?

  Yes

  No

  N/A

• Does the lot match what is on the lot traceability sheet. (Check 3 components)

  Yes

  No

• Are we following FIFO at the line? - Review dates on the boxes available at the line - check oldest

  Yes

  No

  N/A

• Do the labels at the cell / line match the parts being produced?

  Yes

  No

  N/A

• Does the packaging match the packaging instructions?

  Yes

  No

  N/A

• When was the last time the packaging was checked?

• Are the operators adding their employee # on the label or part?

  Yes

  No

  N/A

• Is the communication log ("Black Book") available and completed as required?

  Yes

  No

  N/A

• Are there entries by maintenance or quality. Verify the last weeks entries in the book to support any quality alerts or maintenance activities.

  Yes

  N/A

Customer Incidents Follow - Up

• If this work centre had a recent customer incident, is the corrective action in place and does it work?

  Yes

  No

  N/A

• Are verification stations are being used until validation is complete?

  Yes

  No

• Is the 8D posted at the line?

  Yes

  No

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• Comments

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