Operational Flow Audit (Rev B)

• Company

  

• Site

  Dunfermline

  Houston

  Nusajaya

  Rio

  Singapore

• Audit Area

  Select Assy - High Bay 6 Assy - High Bay 5 Assy - TSM Cell Assy - Valve Cell Assy - FCM Cell Assy - Tbg Hgr Cell

  • Assy - High Bay 6
  • Assy - High Bay 5
  • Assy - TSM Cell
  • Assy - Valve Cell
  • Assy - FCM Cell
  • Assy - Tbg Hgr Cell

• Audit Area

  Select HB Montagem HB Teste HB FFI LB Montagem LB Teste LB FFI Tools Montagem Tools Teste Tools FFI

  • HB Montagem
  • HB Teste
  • HB FFI
  • LB Montagem
  • LB Teste
  • LB FFI
  • Tools Montagem
  • Tools Teste
  • Tools FFI

• Conducted on

  Date

• Auditor Name

• Audit Participants

Section 2.0

• Can anyone in the organization identify if a tool is missing?<br><br>

  Yes

  No

• Detail the reason why

• Does the operator have the correct part he/she needs, when it's needed?<br>

  Yes

  No

• Detail the missing part(s) and the reason why

• Does the operator have the correct tool he/she needs, when it's needed?<br>

  Yes

  No

• Detail the missing tool(s) and the reason why

• Can anyone in the organization identify if a part is missing?<br><br>

  Yes

  No

• Detail the reason why

• Could management gauge the progress of a build by seeing the parts at a particular workstation?<br><br><br>

  Yes

  No

• Detail the reason why

Section 2.1 - Material Delivery Method - Pitch Carts

• Are Pitch Carts in use in each area?<br><br><br><br>

  Yes

  No

• Detail the reason why

• Are Large Components strapped down to Cart<br><br><br><br><br>

  Yes

  No

• Detail the reason why

• Is the load capacity of the pitch cart suitable for the weight of the materials presented?

  Yes

  No

• Detail the reason why

• Are carts in good operating condition and free of damage?

  Yes

  No

• Detail the specific areas of poor condition and/or damage.

• Has each cart had a monthly inspection carried out?<br><br><br><br><br><br>

  Yes

  No

• Detail the reason why

Section 2.2 - Point of Use Tooling - Tool Carts

• Are all tools in place on Shadow Boards<br><br><br><br><br>

  Yes

  No

• Detail the reason why

• Are all visual indicators in place to link the tools to their respective workstation?

  Yes

  No

• Detail the reason why

Section 2.3 - Material Cart Labelling Standards

• Are all Material Carts labelled correctly?<br><br><br><br><br><br>

  Yes

  No

• Detail the reason why

Section 2.5 - Part Templates

• Are material carts populated with Foam Inserts?<br><br><br><br><br><br><br>

  Yes

  No

• Detail the reason why

Section 8.1 - Flow Stoppage within Pitch

• Can you see abnormal flow?

  Yes

  No

• Detail reasons why

• Do operators know what to do when abnormal flow occurs?

  Yes

  No

• Detail reasons why

• Do the operators within the flow solving issues before it effects flow?

  Yes

  No

• Detail reasons why

• If flow is stopped is this sign displayed on the VMB?<br>

  Yes

  No

  N/A

• Detail reasons why

• Was the area flowing at the time of audit

  Yes

  No

Section 8.2 / 8.3 - Flow Stoppages Extending Beyond Pitch

• If Flow is stopped and is effecting Takt, has it been removed from the line into a non flow station?<br>

  Yes

  No

  N/A

• Detail reasons why

• Was the area flowing at the time of audit

  Yes

  No

Section 8.6 - FIFO Rules

• If a FIFO is full, have the preceding cells stopped work?<br><br>

  Yes

  No

  N/A

• Detail reasons why

• Was there still FIFO lane spaces available during the audit?

  Yes

  No

• Are the lanes clearly labelled & marked?<br><br><br>

  Yes

  No

• Detail reasons why

• Are decisions about "what's next?" as simple to make as yes/no?<br><br><br><br>

  Yes

  No

• Detail reasons why

• Does the FIFO indicate what the next product is?<br><br><br><br><br>

  Yes

  No

• Detail reasons why

Flow Rules

• Can you see the flow of product within the value stream?

  Yes

  No

• Detail reasons why

• Are there visuals that tell when work will be delivered/removed?

  Yes

  No

• Detail reasons why

• Do the visuals communicate where the completed work will go next?

  Yes

  No

• Detail reasons why

Section 1.0 - 5S Audits and Checklists

• Are the Operator Daily 5S Checklist and the 5S Weekly Audit Forms in use?<br>

  Yes

  No

• Detail reasons why

• Is the 5S Audit's Visual Management Board (VMB) system in use<br><br>

  Yes

  No

• Detail reasons why

• Are 5S scores consistently meeting or exceeding 3.6?

  Yes

  No

• Detail reasons why

Section 4.1 / 4.2 - 5S Communication Board.

• Is there a 5S Communication Board visible in the area<br>

  Yes

  No

• Detail reasons why

• Is the area being audited a shared service area

  No

  Yes

• Is the Shared Service VMB in use?

  Yes

  No

• Detail reason why

Section 1.1 - Work Station Standards

• Are permanent features marked using solid lines?

  Yes

  No

• Detail reasons why

• Are temporary parking indicated with 90 degree markers?<br>

  Yes

  No

• Detail reasons why

• Are FIFOs marked using the FIFO markings?<br>

  Yes

  No

• Detail reasons why

• 

• Are floors marked in conjunction with the guideline<br>

  Yes

  No

• Detail reasons why

Section 1.1.1 - Floor Label Standards

• Label background must be yellow
  Label text colour must black
  Label font size must be 1.5" high in all caps
  Label must be centred along the edge of the floor marking and must be visible from the main aisle

• Floor Label Naming Convention

  

• Are all areas marked in conjunction with the following?<br>

  Yes

  No

• Detail reasons why

Section 1.1.2 Standard VMB layout

• Standard VMB Layout Image

  

• Does the layout of the VMB match the standard detailed in the SOP?

  Yes

  No

• Detail the non-conformances

• Is the Pitch Plan current and being update by those doing the work?

  Yes

  No

• Detail the reasons why

• Is the "Status to Customer" section of VMB updated at the end of each pitch?

  Yes

  No

• Detail the reasons why

• Do operators capture flow issues and write them on the VMB as they occur?

  Yes

  No

• Detail the reasons why

• Are flow disruption issue resolutions updated?

  Yes

  No

• Detail the reasons why