Part and Process Audit v1

• Supplier Name

• Audit Title

• Document No.

• Performed On

  Date

• Performed by

• Location
  Address

• Supplier Representatives

Supplier Information

• General information

• Core Products

• Annual Volume

• Number of employees (QC employees)

General - Control Systems

• 1. Rate the Suppliers internal Audit process?

• Process should be in place, frequency and scope clearly detailed. <br>Review Supplier Audit Schedulefor overdue items.

  None

  Basic

  Good

  Excellent

• 2. How comprehensive are the available Quality Standards?

• Should be comprehensive and available at every inspection point, are operators/inspectors aware of the content?

  None

  Basic

  Good

  Excellent

• 3. Rate the Suppliers Planned Preventive Maintenance Schedule?

• Does it include all machinery, tools and auxiliary equipment?

  None

  Basic

  Good

  Excellent

• 4. Rate the training that personnel are given for their assigned function?

• Is a training matrix available? Are training records kept, up to date and assessed? Is competency Proven before sign off?

  None

  Basic

  Good

  Excellent

• 5. How strong are the suppliers change management/change controls?

• Changes to manufacturing processes, plant relocation, documentation changes and approval, drawing changes and approval process. Do they include Customer notification and approval requirements?

  None

  Basic

  Good

  Excellent

• 6. Rate the suppliers ability to demonstrate product performance claims?

• Are tests carried out in-house or independent labs? <br>Does it meets recognised standards I.E. international Standards BSI etc

  None

  Basic

  Good

  Excellent

• 7. Rate the suppliers capability to trace product end to end?

• Can the supplier demonstrate effective traceability on an item?

  None

  Basic

  Good

  Excellent

• 8. Rate the suppliers procedure for handling Non-Conformances Report (NCRs)?

• Is each NCR assigned a unique ref to aid traceability?<br>Is a tracking sheet used to monitor responses?

  None

  Basic

  Good

  Excellent

• 9. Does the supplier use a recognised Problem Solving Method, such as 8D, 5WHY, Ishakawa, Taguchi …?

• Review a sample of Supplier's corrective actions, How do they handle customer complaints? Check effectiveness of problem solving with quality monitoring and check control plan has been updated.

  None

  Basic

  Good

  Excellent

• 10. Rate the suppliers process of incorporating learning's from field feedback into their CI activity?

• Improved product design, improved processes

  None

  Basic

  Good

  Excellent

• 11. Rate the Process flow diagram

• Does it clearly show how the product is made? <br>Are all inspection points identified?

  None

  Basic

  Good

  Excellent

• 12. Is there an effective control plan in place?

• Product, process, key characteristics, inspections, parameter checks and set-up checks.<br>Is it Signed off by Key Stakeholders?

  None

  Basic

  Good

  Excellent

• 13. Rate the suppliers advanced quality planning process for product development and change.

• PPAP, AQP, FMEA, Product Approval present and evidence available

  None

  Basic

  Good

  Excellent

• 14. Rate the Process Failure Mode Effects Analysis that has been performed? Are the corrective actions documented, implemented and effective?

• Applicable if Howdens has requested a Process FMEA. Check that FMEA indices are reviewed and updated on a regular basis

  None

  Basic

  Good

  Excellent

• 15. Rate the suppliers capability to monitor process effectiveness and implement changes for improvement?

• Use of SPC, process capability studies, kaizen events.

  None

  Basic

  Good

  Excellent

Purchasing - Supplier Selection & Ordering

• 16. Rate how effective this suppliers process is in selecting, vetting and approving their sub-suppliers?

• Is there a formal process for selection & approval eg, audit, monitoring process?

  None

  Basic

  Good

  Excellent

• 17. Rate the suppliers control of approved sub-suppliers lists for all components, materials and services?

• Is there an approved supplier list?<br>How is the performance of these Sub Suppliers monitored and evaluated?

  None

  Basic

  Good

  Excellent

• 18. Rate the suppliers process for effective correction & Improvement activities within sub-suppliers?

• Eg, rejection notes, 8D report etc.<br>Also check the criteria and responsiveness of sub-suppliers in case of customer complaints, Sub-supplier corrective action requests.Does this supplier instigate a CI Culture within its own supply chain?

  None

  Basic

  Good

  Excellent

• 19. How clearly does the supplier express product requirements in their Purchase Orders?

• Such as: material specifications, important dimensions and tolerances, restricted substances, Shelf Life Etc.

  None

  Basic

  Good

  Excellent

• 20. Have all purchased raw materials been approved by the supplier using a formal process.

• Check Initial Samples reports for each component and material?

  None

  Basic

  Good

  Excellent

Goods In & Raw Materials

• 21. How comprehensive are the available SOPs at GI & Raw Mat. Storage? (Standard Operating procedures

• These should detail, who, where & What happens.<br>Reviewing the process does this accurately reflect what really happens?

  None

  Basic

  Good

  Excellent

• 22. How comprehensive are the inspection instructions?

• Are there visual aids or prompts in place to highlight critical features or processes to the operator/inspector? <br>Are these readily available at every inspection point?

  None

  Basic

  Good

  Excellent

• 23. Rate the storage, indentification and traceability of raw materials

• Should be stored in a dry clean area away from risk of damage<br>How well is Shelf Life Controlled & managed?

  None

  Basic

  Good

  Excellent

• 24. Rate the controls for identifying & segregating non-conforming product from good product.

• Are there any defined quarantined areas/?<br>Are there any potentials for mixing up product? <br>In automated processes does reject product pass over good stock?

  None

  Basic

  Good

  Excellent

• 25. Rate the completion, storage and retention of key product, process & inspection records.

• Records should be complete and legible - have any corrections been signed and dated?<br>Are the records stored for an appropriate length of time?

  None

  Basic

  Good

  Excellent

• 26. Rate the Inbound inspections performed by the supplier? Are they according to the Control Plan?

• Have all critical raw materials been identified?

  None

  Basic

  Good

  Excellent

Production - Manufacturing, Inspection & Packaging

• 27. Rate the work areas for identification, Cleanliness, Organisation & Lighting.

• Is the Area well lit and well maintained.

  None

  Basic

  Good

  Excellent

• 28. Rate the Key Performance Indicators that are in use?

• Safety, quality, delivery, cost, people and environment

  None

  Basic

  Good

  Excellent

• 29. How comprehensive are the available SOPs in the manufacturing process?

• Should also be available at every inspection point

  None

  Basic

  Good

  Excellent

• 30. Rate the suppliers formal start-up/set-up procedure.

• First part should be approved. In case of a long stoppage in operations, start-up procedure should be applied

  None

  Basic

  Good

  Excellent

• 31. Rate the availability of operating and inspection instructions at the point of use, and operators awareness of them.

• Check that they are in conformance with Product/Process Control Plan. Do they adequately detail how to perform the operations and what to inspect? Are they Comprehensive Enough?

  None

  Basic

  Good

  Excellent

• 32. Rate the identification, traceability, control & handling of materials, WIP & Finished Product.

• Does this align with the process flow diagram?<br>Is there any Potential for Mix-up?

  None

  Basic

  Good

  Excellent

• 33. Rate the control of master samples - including usage, availability and correct storage.

• Applicable if Howdens has requested it.

  None

  Basic

  Good

  Excellent or N/A

• 34. Rate the process for root cause analysis and subsequent corrective action of rejects.

• Is there an established 'non conformity' process in use

  None

  Basic

  Good

  Excellent

• 35. Rate the disposal system in place for rejected material/components?

• Check that bins are marked with a colour code for easy identification. Do they capture volumes and types of rejected material/components?

  None

  Basic

  Good

  Excellent

• 36. Rate calibration of measuring equipment.

• Procedure for routine calibration<br>Are there any Out of calibration Items?<br>Are there any instruments Missing?

  None

  Basic

  Good

  Excellent

• 37. Rate packaging effectiveness for protecting the product

• Have Packaging trials been conducted?<br>Is it already in use and proven Historically?<br>Is it suitable for the Howdens W/H & Distribution systems?<br>Moisture, Dirt, Damage, Heat, racking, lifting weight, stack height

  None

  Basic

  Good

  Excellent

• 38. Rate the inspection approach with respect to protecting the customer i.e Howdens

• Does it appropriately detect all potential Failure Modes?<br>Does it Address Previous/known product issues seen in NCR's or Field Issues?

  None

  Basic

  Good

  Excellent

• 39. Is the Frequency/Amount of Inspection Appropriate for the type and level of Product Being Manufactured?
  

• Are there any Safety Critical or Hazardous Aspects?<br>Is 100% inspection needed or feasible?<br>

  None

  Basic

  Good

  Excellent

• 40. How closely does the Control Plan follow the actual process.

• Do the operators know what to do in case of O.O.S?<br>who is responsible, When, Where, How, How often?

  None

  Basic

  Good

  Excellent

Warehousing - Storage & Despatch

• 41. Rate the process to monitor incoming /WIP /finished goods inventory?

• How good is the Stock Rotation System? <br>Look for empty shelves or an excess of one particular item & investigate further, does the system figure match?

  None

  Basic

  Good

  Excellent

• 42. Rate the storage of finished goods

• Should be stored in a dry clean area away from any risk of damage & contamination.

  None

  Basic

  Good

  Excellent

• 43. Does the supplier respect the validity dates for perishable items?

• Adhesives, sealants, paints/lacquers, process aids.<br>Could these have a detrimental effect to product performance if out of date?

  None

  Basic

  Good

  Excellent or N/A

• 44. Rate the identification of finished goods according to Howdens requirements?

• Is there any potential for product mix-ups?<br>How robust is the traceability and labelling of items?

  None

  Basic

  Good

  Excellent

• Bottleneck Analysis

  Yes

  No

• Inspection Specifications/Quality Standards

  Yes

  No

• Visual Factory

  Yes

  No

• Go/No-Go Gauges

  Yes

  No

• Goods inwards Checks

  Yes

  No

• 5s

  Yes

  No

• 1st Off Last off Inspection

  Yes

  No

• Control Plans

  Yes

  No

• Standard Operating Procedures & Records

  Yes

  No

• Basic Testing/Lab

  Yes

  No

• PDCA Process

  Yes

  No

• SPC - Process

  Yes

  No

• Pareto Charts

  Yes

  No

• Ishikawa Diagrams

  Yes

  No

• Approved Supplier Selection

  Yes

  No

• Process Flow Diagrams

  Yes

  No

• FMEA'S

  Yes

  No

• O.E.E.

  Yes

  No

• SPC - Product

  Yes

  No

• Extensive Testing /Lab

  Yes

  No

• Part & Process Audits

  Yes

  No

• Gauge R&R's

  Yes

  No

• KPIs for key manufactured products or manufacturing processes

  Yes

  No

• 8D's

  Yes

  No

• JIT

  Yes

  No

• Andon

  Yes

  No

• SMART Objectives

  Yes

  No

• APQP

  Yes

  No

• DFM / DFSS

  Yes

  No

• Finite Element Analysis

  Yes

  No

• Hoshin Kanri

  Yes

  No

• Value Stream Map

  Yes

  No

• Continuous Flow Processes

  Yes

  No

• Automated Inspection Points

  Yes

  No

• Accredited Test lab Facilities

  Yes

  No

• Kanban

  Yes

  No

• TPM

  Yes

  No

• Heijunka

  Yes

  No

• Jidoka

  Yes

  No

• Poka-Yoke

  Yes

  No

• Product Innovation

  Yes

  No

• SMED

  Yes

  No