Layered Process Audit Template

Shift Audited

Is all material labeled? EXPLANATION: It is important parts are identified to prevent mix-ups. No orphan parts. Scrap must be in red bin, marked red or red tagged. Are tags being completed properly to ensure traceability? REACTION PLAN: If there is a nonconformance, ask the Operator to identify parts.

Are Poka-Yoke and mistake proofing techniques being performed? EXPLANATION: It is important that mistake proofing devices like air seating confirmation are in working order to prevent quality defects. REACTION PLAN: If there is a nonconformance, ask Operator to complete PM Checksheet and/or notify Supervisor and Quality Manager so additional training can be completed.

Are Red Rabbits in gage calibration system and up to date? EXPLANATION: See Operator PM Checksheet for use of Red Rabbits. Conveyors must be used to ensure parts are processed through all operations. REACTION PLAN: If there is a nonconformance, ask Operator to complete PM Checksheet and/or notify Supervisor and Quality Manager so additional training can be completed.

Is Quality Book present? EXPLANATION: Operator should be familiar with the Quality Book to ensure part specifications, work instructions and gaging instructions are followed. REACTION PLAN: Notify Quality Management Representative is Quality Book is missing.

Is Operator on Training Sign-In or Certification Sheet? (If operator was hired prior to 1/17/2017, they may not have a training certification sheet and training may be documented on generic training sign-in sheet.) EXPLANATION: Operator should be signed off on the training sheet when oriented to the job (right away) and again when authorized to work on their own without a trainer's supervision. REACTION PLAN: If there is a nonconformance, ask Operator to work with their trainer to get training sign off and notify Supervisor and Quality Manager.

Is Operator performing checks according to check sheet? EXPLANATION: Choose a dimension/characteristic to verify and ask the Operator to show how they check that dimension. Does gage #/type, frequency and specification match the check sheet? Record operation and dimension #s verified. REACTION PLAN: If there is a nonconformance, notify Operator, Supervisor and Quality Manager so that training can be completed.

Is gage master or gage calibration up to date? EXPLANATION: Calibrations are crucial to ensure that gages are functioning properly. Make sure gage masters are present and properly identified. Record each SG # that was audited. REACTION PLAN: If there is a nonconformance, notify Lab Supervisor or Quality Manager.

Is the first piece up to date? EXPLANATION: The first piece has all dimensions checked by Quality. There should be a part with a pink tag for each operation with the due date for reinspection. For example, if the due date is May 2015 and the date of the audit is October 1st, 2015, the first piece is past due. The month and the year only will be listed on the pink tag. This allows the QC Lab until the end of that month to renew the first piece. REACTION PLAN: If there is a nonconformance, notify Lab Supervisor or Quality Manager so the first piece can be completed.

Have stock piles of forms been removed from workstation? EXPLANATION: Forms need to be printed on an as-needed basis to ensure the latest and greatest revision is being used. REACTION PLAN: If there is a nonconformance, notify Quality Management Representative so that they can remove any stock piles of forms not in use and discard accordingly.

Have all uncontrolled documents been removed from area? EXPLANATION: Any documents that are controlled per QP-7.5-03 (WI, Drawings) will require a red 'Controlled Copy' stamp. Forms will not have 'Controlled Copy' stamp but they are considered controlled as long as they have a form number and revision date. *Excludes anything included in grandfather clause. REACTION PLAN: If there is a nonconformance, notify Quality Management Representative so that all applicable documents can be stamped 'Controlled Copy' in red or issue a CRN (Change Request Notice) to implement document into system.

Is part clean? (IMPREG ONLY) EXPLANATION: UV (Ultra Violet) light is to be used on part to ensure part is free from resin. REACTION PLAN: If there is a nonconformance, notify Supervisor to ensure parts are cleaned according to current work instructions.

Are any Customer Interface Characteristics machined or controlled at this operation? If Yes, what are they and how do they affect the customer? EXPLANATION: Customer Interface Characteristics affect the actual use or performance of the part being produced as it is used by the customer. This could be the ability to assemble the part or its performance in the final buyer's use. REACTION PLAN: If there is a nonconformance, point out the CIC (Customer Interface Characteristic) placard in the cell and review with Operator.

Is Operator wearing the required PPE (Personal Protective Equipment) for their workstation? EXPLANATION: Per Employee Handbook, all direct labor are required to wear safety glasses, safety shoes (closed-toe and leather with slip resistant soles.) REACTION PLAN: If there is a nonconformance, notify Supervisor immediately so that they can make sure operator has the required PPE to operate machine.