Intro

Supplier Information

  • General information

  • Core Products

  • Annual Volume

  • Number of employees (QC employees)

General

General - Control Systems

  • 1. Rate the Suppliers internal Audit process?

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

  • 2. How comprehensive are the available Quality Standards?

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

  • 3. Rate the Suppliers Planned Preventive Maintenance Schedule?

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

  • 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?

  • 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?

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

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

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

  • Can the supplier demonstrate effective traceability on an item?

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

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

  • 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.

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

  • Improved product design, improved processes

  • 11. Rate the Process flow diagram

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

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

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

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

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

  • 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

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

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

Purchasing

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?

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

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

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

  • Eg, rejection notes, 8D report etc.
    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?

  • 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.

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

  • Check Initial Samples reports for each component and material?

Goods in & Raw materials

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.
    Reviewing the process does this accurately reflect what really happens?

  • 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?
    Are these readily available at every inspection point?

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

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

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

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

  • 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?
    Are the records stored for an appropriate length of time?

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

  • Have all critical raw materials been identified?

Production

Production - Manufacturing, Inspection & Packaging

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

  • Is the Area well lit and well maintained.

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

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

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

  • Should also be available at every inspection point

  • 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

  • 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?

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

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

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

  • Applicable if Howdens has requested it.

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

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

  • 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?

  • 36. Rate calibration of measuring equipment.

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

  • 37. Rate packaging effectiveness for protecting the product

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

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

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

  • 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?
    Is 100% inspection needed or feasible?

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

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

Warehousing

Warehousing - Storage & Despatch

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

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

  • 42. Rate the storage of finished goods

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

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

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

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

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

Tools

  • Bottleneck Analysis

  • Inspection Specifications/Quality Standards

  • Visual Factory

  • Go/No-Go Gauges

  • Goods inwards Checks

  • 5s

  • 1st Off Last off Inspection

  • Control Plans

  • Standard Operating Procedures & Records

  • Basic Testing/Lab

  • PDCA Process

  • SPC - Process

  • Pareto Charts

  • Ishikawa Diagrams

  • Approved Supplier Selection

  • Process Flow Diagrams

  • FMEA'S

  • O.E.E.

  • SPC - Product

  • Extensive Testing /Lab

  • Part & Process Audits

  • Gauge R&R's

  • KPIs for key manufactured products or manufacturing processes

  • 8D's

  • JIT

  • Andon

  • SMART Objectives

  • APQP

  • DFM / DFSS

  • Finite Element Analysis

  • Hoshin Kanri

  • Value Stream Map

  • Continuous Flow Processes

  • Automated Inspection Points

  • Accredited Test lab Facilities

  • Kanban

  • TPM

  • Heijunka

  • Jidoka

  • Poka-Yoke

  • Product Innovation

  • SMED

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