Information
-
Audit Title
-
Type of audit:
- System
- Process
- Product
- Performance
- Legal Compliance
-
Personnel
-
Client / Site:
-
Certifications
- ISO 9000
- ISO 13485
- ISO 14001
- OHSAS 18001
-
Location
-
Conducted on:
-
Prepared by:
EXECUTIVE SUMMARY:
-
undefined
RECOMMENDATIONS:
-
undefined
FACILITY
-
<50% Very Poor - IMMEDIATE Corrective Action Required
51-70% Poor - Corrective Action Required
71-80% Average - Improvement Required
81-90% Good - Improvement Recommended
>91% Very Good - Monitoring Recommended
SAFETY & ENVIRONMENT
WORK ENVIRONMENT
-
Is the general working environment in a safe & health condition for operators?
-
NO spilled hazardous materials or liquids?
-
Combustible scrap, debris & waste stored safely and removed?
-
Work areas adequately illuminated?
MACHINE GUARDING
-
Is machinery being operated properly guarded / secured to prevent injuries to operators?
-
Power shut-off switch within reach of the operator's position?
-
Foot-operated switches guarded to prevent accidental actuation?
-
Emergency stop buttons colored red and working?
-
Moving chains and gears properly guarded?
HAZARDOUS CHEMICAL EXPOSURE
-
Is the operator not exposed to, or adhering to safe working practices in terms of chemical exposure?
-
Eye wash fountains and safety showers provided?
-
All containers, such as vats, storage tanks, etc., labeled?
-
All staff are using relevant PPE and have clean uniforms. Personal protective clothing and equipment Std?
-
No eating in the workplace?
OPERATOR SAFETY
-
Is the operators protected against the necessary safety risks in the work place?
-
Floor & Wall Openings: floor openings guarded?
-
Forklifts / Vehicles: warning horn, trained personnel?
-
Noise: hearing protective equipment?
-
Spray Machines: adequate ventilation?
-
Aisles & Passage Ways: aisles and passageways kept clear, marked as appropriate, wet surfaces covered with non-slip materials?
LOCKOUT/TAGOUT
-
Is all machinery or equipment blocked or locked-out during cleaning, servicing, adjusting or setting up operation, whenever required?
-
Lock Out Tag available / not accessible?
-
Safe job procedure established and rigidly followed?
WORK PLACE ORGANIZATION (5S)
SORT / ORGANIZATION
-
Is the workplace well organized?
-
Unneeded equipment, tools, furniture, etc. are present?
-
Unneeded items are on walls, bulletin boards?
-
Items are present in aisle ways, stairways, corners?
-
Unneeded inventory, supplies, parts, or materials are present?
-
Safety hazards ( water, oil, chemicals, machines ) exist?
SET IN ORDER / ORDERLINESS
-
Are all work areas maintained in a state of order?
-
Correct places for items are not obvious, Items are not in there correct places?
-
Aisle ways, workstations, equipment locations are not indicated?
-
Items are not put away immediately after use?
-
Height and quantity limits are not obvious?
SHINE / CLEANLINESS
-
Are all work areas maintained in a state of cleanliness?
-
Cleaning, and looking for ways to keep it clean and organized?
-
Floors, walls, stairs, and surfaces are not free of dirt, oil and grease?
-
Equipment is not kept clean and free of dirt, oil, and grease?
-
Cleaning materials are not easily accessible?
-
Lines, labels, signs, etc. are not clean and unbroken?
-
Other cleaning problems ( of any kind ) are present?
STANDARDIZE / ADHERENCE
-
Is the necessary work standards, visual aids available, and adhered to?
-
Maintain the workplace as per standard visual aids?
-
Necessary information is not available, All standards are not known and visible?
-
Checklists don't exist for all cleaning and maintenance jobs?
-
All quantities and limits are not easily recognizable, How many items can't be located in 30 seconds?
PROCESS CONTROL / FPF
DOCUMENTATION / TOOLS
-
Is the necessary documentation and standards available?
-
Process / FPF Manual available and up to date?
-
Visual Aids available and current?
-
Gauges and Tools available & calibrated?
-
Forms for FPF Available & Legible?
SETUP / 1ST PIECE APPROVAL
-
Is the start of shift setup and 1st piece approval carried out?
-
All Machine Check Points Completed prior to start of 1st run?
-
All Process & Product Points Completed prior to start of run & Signed?
-
First Piece Approval part available and stamped correctly.
PROCESS CONTROL
-
Is the process in control against the set standards, or process parameters?
-
Process setup as per Process/work order / WI?
-
Process/work order signed and updated?
-
SPC Charts updated and actions taken on deviations, FPF Documents updated and signed
PROCESS MONITORING / PERFORMANCE
-
Is the FPF Performance monitored, at regular intervals?
-
Process Performance Boards maintained, all required information posted on Boards?
PROCESS VALIDATION
-
Is the FPF 5P Audit carried out and actioned?)
-
FPF Audit Checklist completed and current?
-
FPF Performance Chart updated?
-
Non conformance communicated and actioned, Escalation of failures (if needed)
CUSTOMER ISSUES & ACTIONS
-
Are operators aware of customer complaints and is actions taken?
-
Quality Alert posted and Current?
-
Customer Reject Samples available?
-
Actions taken based on corrective actions documented?
STANDARDIZED WORK
WORK STANDARD
-
Is the work standard available with the necessary information?
-
Cycle Time?
-
Machine Layout?
-
Order of Operations?
-
Work Sequence for the operator (visual)?
-
Quality Checks?
-
Safety Precautions?
-
Trained operator?
WORK SEQUENCE
-
Is the operator conducting the work as stipulated in the STD Work instruction?
-
Work activity / sequence against std instruction?
-
Devices / Tools / Machinery used correctly?
-
Continuous Flow of product?
-
Cycle Time is kept to the standard (check SWI)?
STANDARD WIP
-
Is there any material WIP, or visible material flow issues?
-
Imbalanced parts or unfinished work pieces?
-
Excessive WIP / Material before and after process?
-
Next process waiting for material?
WASTE MANAGEMENT
-
Is there any evidence of 7 wastes and action taken to correct?
-
Transportation (moving products that is not actually required to perform the processing)?
-
Inventory (all components, work-in-progress and finished product not being processed)?
-
Motion (people or equipment moving or walking more than is required to perform the processing)?
-
Waiting (waiting for the next production step)?
-
Overproduction (production ahead of demand)?
-
Over Processing (due to poor tool or product design creating activity)?
-
Defects (the effort involved in inspecting for and fixing defects)?
OPERATIONAL PERFORMANCE
-
Is the performance tracked, maintained and action taken on deviations?
-
Performance standards established and known, Downtime sheets, Hourly output sheets, and tracking?
-
Actual performance in line with targets Internal PPM, FPF%, Productivity?
Close-Out
ACTION DECK
-
SAFETY & ENVIRONMENT
SHE#
-
Action
-
By Whom
-
By When
-
5S / WORK PLACE ORGANIZATION
5S#
-
Action
-
By Whom
-
By When
-
PROCESS CONTROL / FPF
FPF#
-
Action
-
By Whom
-
By When
-
STANDARDIZED WORK
SWI#
-
Action
-
By Whom
-
By When
SIGNATURES
-
Auditor / Assessor
-
Auditee
Signature#
-
Add signature
