Manufacturing Process Audit

• Audit Title

• Site conducted

  Select

• Conducted on

  Date

• Prepared by

• Location

Assessing Order

• Are parts clearly labeled?

  Pass

  Fail

  N/A

• Are parts unwrapped and in correct bins?

  Pass

  Fail

  N/A

• Are parts spread loose around the build area?

  Yes

  No

• Is a form of tool mangament in place? (Tools clearly labeled or have a place to be returned)

  Pass

  Fail

  N/A

Assessing Cleanliness

• Are the Work Surfaces Clean

• Is the Floor Space Clean

• Is the Product Clean

• Input any additional comments for this section (Cleanliness and Order)

• Is there a clear performance metric or target for the day, week or month?

  Pass

  Fail

  N/A

• Is there a clear visual managment tool that outlines who is doing what job today?

  Pass

  Fail

  N/A

• Is it clear who is working today and whether the manufacturing cell has enough people to achieve its target?

  Pass

  Fail

  N/A

• Is there daily/weekly or monthly quality issues reported and easily visible?

  Pass

  Fail

  N/A

• Is there actions in place or a pareto of these issues available?

  Pass

  Fail

  N/A

• Quality Alerts Present or Space for alerts?

  Pass

  Fail

  N/A

• Is there daily/weekly or monthly near misses or accidents recorded

  Pass

  Fail

  N/A

• Is there a target in place?

  Pass

  Fail

  N/A

• Is there daily/weekly or monthly scrap recorded and easily visible?

  Pass

  Fail

  N/A

• Is there a target in place?

  Pass

  Fail

  N/A

• Input any additional comments for this section (Visual Management)

• Does the operator know how to raise an issue?

  Pass

  Fail

  N/A

• Input any additional comments for this section (QMS)

Works Orders

• Operators Working to Works Orders/Clear Job Cards present

  Pass

  Fail

  N/A

• Has the due date on the works order passed?

  Yes

  No

• Do the operations have time associated with them?

  Pass

  Fail

  N/A

• Does the WO have the drawing attached?

  Pass

  Fail

  N/A

• Does the works order revision/PN match the drawing

  Pass

  Fail

  N/A

• Is the drawing correct?

  Pass

  Fail

  N/A

• Are all operations required and followed?

  Pass

  Fail

  N/A

Inspection Documentation

• is it clear the finished products conform to specification?

  Pass

  Fail

  N/A

• Is the inspection documentation handwritten?

  Select Handwritten Mixture of Handwritten and Saved on PC/Database Saved on PC/Database

  • Handwritten
  • Mixture of Handwritten and Saved on PC/Database
  • Saved on PC/Database

Standard Operating Instructions

• Can the operator show you the SOPS?

  Pass

  Fail

  N/A

• Are the SOPS followed?

  Pass

  Fail

  N/A

• Are the SOPS easily visible/straight forward to find?

  Pass

  Fail

  N/A

Training Records

• Does the operator feel confident with the job? (Ask Q)

  Pass

  Fail

  N/A

• Is there a training matrix available?

  Pass

  Fail

  N/A

• Is the training matrix clearly visible for all?

  Pass

  Fail

  N/A

• Is there recorded training for specific competencies in place? E.g. Soldering, Crimping

  Pass

  Fail

  N/A

• Have the operators signed any training records?

  Pass

  Fail

  N/A

• Is there a training plan in place? (Via Rotation, mentoring)

  Pass

  Fail

  N/A

• Input any additional comments for this section (Documentation and MPC)

• Is there a Process Flow Document present and clearly visible?

  Pass

  Fail

  N/A

• Does it match the routing?

  Pass

  Fail

  N/A

• Input any additional comments for this section (Layout and Flow)

Inventory

• Has the operator got enough parts to complete the days production?

  Pass

  Fail

  N/A

• Is it clear and known how inventory replenished

  Pass

  Fail

  N/A

• Input any additional comments for this section ( Inventory & WIP)

Work In Progress

• Is there suitible WIP available between the stations? I.E are the bottlenecks fed or are processes waiting?

  Pass

  Fail

  N/A

• Is there a build up of WIP because of a line stoppage?

  Yes

  No

• What's stopping the progression of the product?

• Is there too much WIP? (Hint: check the date on the WO is it due soon or months in the future?)

  Yes

  No

• Sample a few tools, have any got tool numbers? (e.g. Torque Wrenches, Multimeters)

  Yes

  No

  N/A

• Have they got calibration labels?

  Pass

  Fail

  N/A

• Are they in date?

  Pass

  Fail

  N/A

• Is the condition of the equipment (Tools/Tooling) adequate? (e.g. non-rounded allen keys or snapped screwdrivers)

  Pass

  Fail

  N/A

• Input any additional comments for this section (Equipment and TPM)

• Is there risk assessments available where required?

  Pass

  Fail

  N/A

• Does the operator/s know the process for reporting health and safety concerns?

  Pass

  Fail

  N/A

• Are the fire exits clearly located?

  Pass

  Fail

  N/A

• Is there a site map detailing fire escape routes, extinguisher locations and first aid stations?

  Pass

  Fail

  N/A

• Input any additional comments for this section (H&S)

• Have you spotted any 'best practices'? (Perhaps an operator going above and beyond to ensure quality outcomes)

  Yes

  No

• Notify the operator of the good work and establish whether there is scope to role this best practice out officially.