Process Audit

• Uttam Foundries & Ispat Pvt. Ltd.

• Report Number

• Prepared by

• Audit started on

  Date

• Part Name

• Item Code (UF)

• Drawing number (customer) with revision

• Purpose of audit

  Select

• Latest revision Balooned Drawing hard copy available and stored in master file. Confirm with purchase order

  Yes

  No

  N/A

• Latest revision Balooned drawing soft copy available in master folder and document master updated

  Yes

  No

  N/A

• Latest revision stage drawings are available and issued to production

  Yes

  No

  N/A

• Stage drawings match with FSIR, IPIR in all respects. No dimensions missing

  Yes

  No

  N/A

• All stage drawings are listed and controlled with revision numbers and details and added in document master

  Yes

  No

  N/A

• Obsolete drawings and documents in hard master file are marked clearly and disposed off

  Yes

  No

  N/A

• Obsolete drawings and documents in soft master folder are marked clearly and stored in correct folder

  Yes

  No

  N/A

• PFD and control plan available in the latest format with latest revision and document master updated

  Yes

  No

  N/A

• Control method of KCC parameters in the control plan follows the Poka yoke, SPC or 100% inspection rule

  Yes

  No

  N/A

• Ballooned dimensions in Ballooned drawing and control plan match

  Yes

  No

  N/A

• LIR matches with control plan in all respects including tolerances, MMD (with Least count) and characteristic

  Yes

  No

  N/A

• Audit summary sheet matches with control plan in all respects including tolerances, MMD (with Least count) and characteristic

  Yes

  No

  N/A

• All excel files in master folder are in the latest excel format and file type

  Yes

  No

  N/A

• Drawings of all jigs, fixtures and special tools available and controlled

  Yes

  No

  N/A

• Customer approved packaging standard available and controlled

  Yes

  No

  N/A

• Solid model of Casting, pattern, layout and gating available and controlled

  Yes

  No

  N/A

Batch sheet verification according to control plan

• Batch sheet matches with control plan in all respects including tolerances, MMD (with Least count), characteristic, process flow, inspection frequencies, etc.

  Yes

  No

  N/A

• Operation sequence, numbering and nomenclature with machine type mentioned and matches with CP

  Yes

  No

  N/A

• IPIR matches with control plan in all respects including tolerances, MMD (with Least count), characteristic, inspection frequencies, etc.

  Yes

  No

  N/A

• FSIR matches with control plan in all respects including tolerances, MMD (with Least count), characteristic, inspection frequencies, etc.

  Yes

  No

  N/A

• Correct format of batch sheet is used and pdf print copy available in soft is of the latest revision?

  Yes

  No

  N/A

• Does PDI report match with the Component quality standard provided by customer? Is it appropriate?

  Yes

  No

  N/A

• Operation 90 (Manufaturing inspection) and 100 (PDI) added in batch sheet

  Yes

  No

  N/A

• Is PDI and Visual encyclopedia page available for this part for all major characteristics?

  Yes

  No

  N/A

• If part is bought out, has PDI check sheet been provided to supplier with confirmation of receipt?

  Yes

  No

  N/A

• Does the actual process flow match with the approved PFD

  Yes

  No

  N/A

• Are approved NC programs being used

  Yes

  No

  N/A

• Is the correct machinery and equipment, as defined in control plan, being used

  Yes

  No

  N/A

• Jigs and fixtures being used are approved and as defined in control plan

  Yes

  No

  N/A

• Measuring and monitoring devices being used are as per control plan

  Yes

  No

  N/A

• Calibrated jigs fixtures are being used with ID clearly visible

  Yes

  No

  N/A

• Calibrated MMD are being used wit ID clearly visible

  Yes

  No

  N/A

• Are the MMD being used adequate for the tolerance of the parameters being checked?

  Yes

  No

  N/A

• If part is bought out, Quality of receipt inspection report

• If part is bought out, is the supplier sending duly completed PDI reports with each lot?

  Yes

  No

  N/A

• Quality of FSIR filling

• Quality of IPIR filling

• Quality of PDI filling

• Verify whether control method of KCC parameters as defined in CP is being completely followed

  Compliant

  Non-Compliant

  N/A

• Verify effectiveness of applied Poka Yoke as in control plan, if any

  Good

  Fair

  Poor

  N/A

• Packaging being done as per packaging standard

  Yes

  No

  N/A

• Audit complete date

  Date