Windsor LPA level 3-Manufacturing Focus

• Work Centre

  Select

• Shift

  Days

  Afternoons

  Midnights

• Part Number

• Prepared by

• Auditor-Enter First Name/Last Name of person completing the audit

• Audit Participant(s)

• Type of Audit (Manager or Supervisor)

  Manager

  Supervisor

• Conducted on

  Date

People (S)

• Are all personnel using all the posted Personal Protective Equipment?

  Yes

  No

  NA

• Has the operator been trained to the requirements of the job & is the versatility training matrix updated?

  Yes

  No

• Does it include temps or contract personnel?

  Yes

  N/A

• Are they on the versatility matrix?

  Yes

  No

Standardization / Built in Quality (Q,T,C,M)

• Are the work instructions (JES) for the parts being produced at the station or in binders located at Production boards?

  Yes

  No

• Are they being followed? Observe 3 cycles

  Yes

  No

• Are the operators aware of the location of the work instructions?

  Yes

  No

• Are the alarm limits for part defects posted & mentioned in the standardized work instructions? ( There is to be a posting in the area that indicates once they reach a X# of parts they are to call for support)

  Yes

  No

• Are the operators aware of what the alarm limits are?

  Yes

  No

• Is there evidence that verification station(s) are used following significant physical damage to equipment when recovery took longer than 24 hours and the quality of the final product was compromised? Check the black communication book for any entries by maintenance or manufacturing engineering, ask the team leader how long the line was down. (MAFACT 2.05 3c)

  Yes

  No

  NA

• Is there evidence of standardized work instructions (combination table, standardized work chart & job element sheets) available at the verification station(s) for the work being done?

  Yes

  No

• Are they being followed & is the training matrix posted & up to date?

  Yes

  No

• Has the safety check sheet been verified?

  Yes

  No

  NA

• Can the operator show you how they do the checks?

  Yes

  No

• For error proofing/error detection device verification, are master/boundary samples (red rabbit) available for each customer attachment point? (MAFACT 2.06-3c)

  Yes

  No

  NA

• Are they in good condition & clearly identified?

  Yes

  No

• Are they completed as per the required schedule? (MAFACT 2.06-3c)

  Yes

  No

• Are results recorded? Check data back 1 month

  Yes

  No

• Do the numbers on the error proofing devices boundary samples match what is on the boundary sample sheet

  Yes

  No

• Is the reaction plan available for the error proofing devices (boundary samples) should they not work as intended? (MAFACT 2.06-3c)

  Yes

  No

• Are process settings and/or parameters being monitored? Examples are screw gun settings, grease settings. Choose N/A if there is no equipment/parameters to monitor at the line

  Yes

  No

  NA

• Are the parameters settings in specification?

  Yes

  No

• Have the equipment changeover checklists been verified? NOTE: This only applies to equipment changeovers that take longer than 15 min.

  Yes

  No

  NA

• Is TPM being completed as per the plan/schedule? (MAFACT 3.09-2d)

  Yes

  No

  NA

• Is there any screwdriving equipment at the line

  Yes

  N/A

• Are we monitoring the torque?

  Yes

  No

• Is the calibration sticker up to date?

  Yes

  No

• Is the screw torque with in spec-parameters are on first off?

  Yes

  No

• Are key severity items being controlled?

  Yes

  No

  NA

• Are customer interface characteristics documented on a special product matrix & displayed or in a line binder? (MAFACT 2.04 3c)

  Yes

  No

• Does the matrix list all, where/how checked, frequency & the way the Customer will use the part? Are the special characteristics indicated LV1/LV2/LV3 for this work centre?

  Yes

  No

• Are scrap racks/bins/lock boxes present & parts clearly marked & defective parts marked on the scrap sheets/electronically? (MAFACT 2.02 3d)

  Yes

  No

  NA

• Are the parts clearly marked?

  Yes

  No

• Are the defective parts recorded on scrap sheets or electronically?

  Yes

  No

• Are there high occurrences of failures at this line? Describe what you have found

  Yes

  No

• Is there lot traceability on the finished good parts? Confirm with Quality location of & type of lot traceability (ie: date code in fishmouth)

  Yes

  No

• Do the labels at the line/cell match the parts being produced? (MAFACT 2.02-3d)

  Yes

  No

• Are the operators adding their employee # on the label or part? If this is an autopack line choose NA

  Yes

  No

  NA

• Is the communication log ("Black Book") available and completed as required?

  Yes

  No

• Are there entries by maintenance or quality. Verify the last weeks entries in the book to support any quality alerts or maintenance activities.

  Yes

  No

• Is the idling procedure available & followed? Verify the shift handover checklist on the communication board (energy reduction)(MAFACT 6.10 1d)

  Yes

  No

  NA

• Can the team leader show you they are actively engaged in the CI/ employee suggestion program (MAFACT 6.11-2b)

  Yes

  No

• What evidence was show to validate their statement? An example would. be a process change or modification through a work order written by that person.

More

• Have the results of this audit been communicated to the manager/supervisor/team leader? Only notification to 1 required.

  Yes

  No

• Name of person communicated results to

• Why were the results not communicated?

Sign-off

• Signature

  Sign

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