Woodstock Layered Process Audit - Level 4 - duplicate

What Level LPA Will You Be Conducting?

LPA Level 4 - Advanced Techs, Quality Techs and Production Supervisors
LPA Level 3 - Engineers, Office Staff, and Department Managers
LPA Level 2 -Plant Manager
LPA Level 1 - Corporate Representative

Area to be audited:

Which Shift are you Auditing on?

Safety in everything we do. A safe working environment is the most critical aspect of any job. Is the Operator wearing all PPE designated for the safe operation of the ablation line? High visibility vest or uniform, cut resistant sleeves and gloves, earplugs, safety shoes, and safety glasses are all required.

Inform the Production Supervisor before continuing the audit and running the line. This needs to be corrected immediately before any operation can continue.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items b, d, f, and h in the Destacking Area. Break the light curtain of all 4 destacking bays and confirm that the red fault light triggers. Are all destacking bay's fault lights working as intended?

Take a video of the destacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the destacking bays, not all 4.

Inform the Production Supervisor and Maintenance Manager.

Take a video of the destacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the destacking bays, not all 4.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items b, d, f, and h in the Destacking Area. Break the light curtain of all 4 destacking bays and confirm that the red fault light triggers. Are all destacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager

Take a video of the destacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the destacking bays, not all 4.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items b, d, f, and h in the Destacking Area. Break the light curtain of all 4 destacking bays and confirm that the red fault light triggers. Are all destacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the destacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the destacking bays, not all 4.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items b, d, f, and h in the Destacking Area. Break the light curtain of all 4 destacking bays and confirm that the red fault light triggers. Are all destacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager

Take a video of the destacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the destacking bays, not all 4.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the hazard been reported, and if possible resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items b, d, f, and h in the Destacking Area. Break the light curtain of all 4 destacking bays and confirm that the red fault light triggers. Are all destacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager

Take a video of the destacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the destacking bays, not all 4.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items b, d, f, and h in the Destacking Area. Break the light curtain of all 4 destacking bays and confirm that the red fault light triggers. Are all destacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager

Take a video of the destacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the destacking bays, not all 4.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items b, d, f, and h. Break the light curtain of all 4 destacking bays and confirm that the red fault light triggers. Are all destacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the destacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the destacking bays, not all 4.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items b, d, f, and h in the Destacking Area. Break the light curtain of all 4 destacking bays and confirm that the red fault light triggers. Are all destacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager

Take a video of the destacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the destacking bays, not all 4.

A place for everything and everything in it's place. Is the Ablation cell following the 5S practices? (Select Yes or No to see more options)

SORT - Eliminate what is not needed. Is there any evidence on the line of tools or items that are not required? Take a photo of any items that should be red tagged or removed from the cell. If there is no issues take photos of the cell showing good SORT practices.

SET IN ORDER - Organize whatever remains by neatly arranging and identifying parts and tools for ease of use. Is the Station organized? Do all tools required for the job have a designated place and is that tool in that place? If there are any items that do not have a place or are not in their place take a photo of them. If not take photos representing good SET IN ORDER practices.

SHINE - Is the work area clean? Is the HMI cabin clean of any dirt and debris? Is the floor around the cell clean with no edge protectors or garbage on the floor? Take a photo for any issue the cell has with SHINE. If there are no issue please take photos representing good SHINE practices.

STANDARDIZE - Schedule regular cleaning and maintenance by conducting daily cleaning of the cell. Is the AM checklist being followed? Take a photo of the AM checklist.

Layered Process audits are designed to verify process conformance. In the Laser cell section of the AM checklist ask the Manufacturing Technician to show you how they validate item m. Once they show you preform the check yourself, visually inspect rollers for wear and tear and if you find the roller in an unusable condition ask maintenance to replace and contact Supervisor. Where the rollers Ok? Did the Manufacturing Technician inspect the roller correctly? Take a photo of the roller condition.

SUSTAIN - Make 5S a way of life by forming the habit of always following the first four S’s. Has the Manufacturing Technician received the 5S training?

Are there any personal items on the line?

We leave the same way we came in. Is the Manufacturing Technician Locking out the cell when going in to the machine? Ask the Manufacturing Technician to demonstrate the LOTO procedure if you have not witnessed them locking out yet.

Inform the Production Supervisor, Production Manager and Plant Manager Immediately. The Line and Audit cannot continue to operate until this is addressed.

The customer is our focus. The Quality of our parts is how we ensure our customer is protected. In process checks are required by our customers to be completed every 30 minutes. Ask the Manufacturing technician to locate their IP check for all parts that were ran on this shift. Has the IP Sheet been completed? Take a photo of the IP sheet on the line.

Interview the Manufacturing Technician asking why the IP checks have not been completed.

All IP check sheets need to be the most up to date version from IQS. Old revisions of IP sheets do not include recent customer directions or concerns. Is the Operator using the most up to date IP sheet? Use the reference below to verify.

The In Process Check sheet asks Manufacturing Technicians to check for narrow, wide, deep and shallow ablation. Check a part at the end of the line, do you see any defects?

Call the Quality Technicians and Production Supervisor on shift to verify the part, if there is a concern the run may need to be re-ablated, re-brushed or put on hold. Pause the line until a decision is made.

Aluminum on the edge (ALoE) of the blank will cause the tensile strength of a welded seam to weaken greatly. If the weld seam is weaker then the base material of a part we will have a catastrophic failure at our customer. Does the Manufacturing Technician know how to properly check for ALoE?

Demonstrate the correct way to check an edge for ALoE. Then ask the Manufacturing Technician to show you the correct way of checking a part. If you are not sure how to check for ALoE call a Quality Technician on shift to demonstrate the correct process.

Check two finished pallets that have recently been ablated for ALoE. Is there any ALoE present on these pallets?

Call the Quality Technician on shift. If they agree that there is an unacceptable amount of Aluminum on the edge of the blanks they will flag the pallets for re-brushing. A new FO verifying no ALoE will need to be submitted to QA.

Validation tags are used by Manufacturing Technicians in order to verify the quality of their product to their customer. Is the Manufacturing Technician using the correct version of the validation tags, and is the validation tag filled in? Take a photo of the validation tag if possible.

An example of the most recent version of 02436-WOS

Ask the Manufacturing Technician what our Quality Policy is. Please record their answer in the space provided.

Did the Manufacturing Technician know the quality policy?

Yes
No
Not Sure/ I do not know the Quality Policy

Explain FIRST to the Manufacturing Technician.

Safety in everything we do. A safe working environment is the most critical aspect of any job. Is the Operator wearing all PPE designated for the safe operation of the ablation line? High visibility vest or uniform, cut resistant sleeves and gloves, earplugs, safety shoes, and safety glasses are all required.

Inform the Production Supervisor before continuing the audit and running the line. This needs to be corrected immediately before any operation can continue.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, and c from section 2. Inspect the function of the Safety doors in the weld cabin. Open the door, press the e-stop and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the weld HMI showing the power to the cell is currently on. Then continue the video with you activating the Estop on one of the safety doors. Once the E-stop is engaged pan over to the HMI and record the power now being shut off.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you activating the Estop on one of the safety doors. Once the E-stop is engaged pan over to the HMI and record the power now being shut off.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, and c from section 2. Inspect the function of the Safety doors in the ablation cabin. Open the door, press the e-stop and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you activating the Estop on one of the safety doors. Once the E-stop is engaged pan over to the HMI and record the power now being shut off.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, and c from section 2. Inspect the function of the Safety doors in the ablation cabin. Open the door, press the e-stop and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you activating the Estop on one of the safety doors. Once the E-stop is engaged pan over to the HMI and record the power now being shut off.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, and c from section 2. Inspect the function of the Safety doors in the ablation cabin. Open the door, press the e-stop and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you activating the Estop on one of the safety doors. Once the E-stop is engaged pan over to the HMI and record the power now being shut off.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the hazard been reported, and if possible resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, and c from section 2. Inspect the function of the Safety doors in the ablation cabin. Open the door, press the e-stop and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you activating the Estop on one of the safety doors. Once the E-stop is engaged pan over to the HMI and record the power now being shut off.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, and c from section 2. Inspect the function of the Safety doors in the ablation cabin. Open the door, press the e-stop and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you activating the Estop on one of the safety doors. Once the E-stop is engaged pan over to the HMI and record the power now being shut off.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, and c from section 2. Inspect the function of the Safety doors in the ablation cabin. Open the door, press the e-stop and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you activating the Estop on one of the safety doors. Once the E-stop is engaged pan over to the HMI and record the power now being shut off.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, and c from section 2. Inspect the function of the Safety doors in the ablation cabin. Open the door, press the e-stop and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you activating the Estop on one of the safety doors. Once the E-stop is engaged pan over to the HMI and record the power now being shut off.

A place for everything and everything in it's place. Is the Ablation cell following the 5S practices? (Select Yes or No to see more options)

SORT - Eliminate what is not needed. Is there any evidence on the line of tools or items that are not required? Take a photo of any items that should be red tagged or removed from the cell. If there is no issues take photos of the cell showing good SORT practices.

SET IN ORDER - Organize whatever remains by neatly arranging and identifying parts and tools for ease of use. Is the Station organized? Do all tools required for the job have a designated place and is that tool in that place? If there are any items that do not have a place or are not in their place take a photo of them. If not take photos representing good SET IN ORDER practices.

SHINE - Is the work area clean? Is the HMI cabin clean of any dirt and debris? Is the floor around the cell clean with no edge protectors or garbage on the floor? Take a photo for any issue the cell has with SHINE. If there are no issue please take photos representing good SHINE practices.

STANDARDIZE - Schedule regular cleaning and maintenance by conducting daily cleaning of the cell. Is the AM checklist being followed? Take a photo of the AM checklist.

Layered Process audits are designed to verify process conformance. In the Laser cell section of the AM checklist ask the Manufacturing Technician to show you how they validate item n. Once they show you preform the check yourself, visually inspect these three conveyors for damages, contact maintenance and inform supervisor if find any major damages. Where the conveyers Ok? Did the Manufacturing Technician inspect the conveyer correctly? Take a photo of the conveyer condition.

SUSTAIN - Make 5S a way of life by forming the habit of always following the first four S’s. Has the Manufacturing Technician received the 5S training?

Are there any personal items on the line?

We leave the same way we came in. Is the Manufacturing Technician Locking out the cell when going in to the machine? Ask the Manufacturing Technician to demonstrate the LOTO procedure if you have not witnessed them locking out yet.

Inform the Production Supervisor, Production Manager and Plant Manager Immediately. The Line and Audit cannot continue to operate until this is addressed.

Ask the Manufacturing Technician why Autonomous Maintenance is important and why they are asked to completed it at the start of every shift. Please record their answer.

Autonomous Maintenance (AM) is designed to identify critical issues before they lead to critical equipment failures. For this reason AM checks need to be completed at the start of every shift. In the next questions of the LPA we will validate that the AM checks have been completed diligently. Firstly ask the Manufacturing technician to locate the AM checklist. Has the sheet been fully filled in?

Ask the Manufacturing Technician to fill in their required AM checks before proceeding with the audit. Ask the operator why the AM checks were not completed at the beginning of the shift.

Was there any items flagged requiring immediate action?

Ask the Manufacturing Technician what was done to resolve the issue.

Work with the Manufacturing Technician to verify items b, i, j, and k from Section 1 - Laser Cell Area. Follow all steps in the key points section in order to verify each item. Take a video of of the validation process for item b, ensuring to capture any debris that might have built up in the ablation hoses and the inspection of the cross jet suction. During the validation process did you find any non-conformances? ( dirty hoses, dirty laser lenses, any worn brushes etc.)

Describe the non-conformance below. Ask the Manufacturing Technician to resolve the issue before continuing with the audit.

Work with the Manufacturing Technician to verify items a and b from Section 2 - Ablation Dust Collector. At the back of the line there are two blue drums that collect both the wet and dry dust from the ablation lines. Follow the key points section to complete the verification. Once each drum is open take a picture showing the current waste levels. During the validation process did you find any non-conformances?

Ask the Manufacturing Technician to correct the non-conformance before proceeding with the audit.

Safety in everything we do. A safe working environment is the most critical aspect of any job. Is the Operator wearing all PPE designated for the safe operation of the ablation line? High visibility vest or uniform, cut resistant sleeves and gloves, earplugs, safety shoes, and safety glasses are all required.

Inform the Production Supervisor before continuing the audit and running the line. This needs to be corrected immediately before any operation can continue.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, d, and e from section 3. Inspect the function of the Safety doors in the brushing area of the ablation line. Open the door and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you opening one of the safety doors. Once the door is open pan over to the HMI and record the power now being shut off.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, d, and e from section 3. Inspect the function of the Safety doors in the brushing area of the ablation line. Open the door and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you opening one of the safety doors. Once the door is open pan over to the HMI and record the power now being shut off.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, d, and e from section 3. Inspect the function of the Safety doors in the brushing area of the ablation line. Open the door and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you opening one of the safety doors. Once the door is open pan over to the HMI and record the power now being shut off.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, d, and e from section 3. Inspect the function of the Safety doors in the brushing area of the ablation line. Open the door and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you opening one of the safety doors. Once the door is open pan over to the HMI and record the power now being shut off.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the hazard been reported, and if possible resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, d, and e from section 3. Inspect the function of the Safety doors in the brushing area of the ablation line. Open the door and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you opening one of the safety doors. Once the door is open pan over to the HMI and record the power now being shut off.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, d, and e from section 3. Inspect the function of the Safety doors in the brushing area of the ablation line. Open the door and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you opening one of the safety doors. Once the door is open pan over to the HMI and record the power now being shut off.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, d, and e from section 3. Inspect the function of the Safety doors in the brushing area of the ablation line. Open the door and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you opening one of the safety doors. Once the door is open pan over to the HMI and record the power now being shut off.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, d, and e from section 3. Inspect the function of the Safety doors in the brushing area of the ablation line. Open the door and confirm that the master power at the HMI station drops out for each door. Does the power at the HMI shut off for each safety door?

Inform the Production Supervisor and Maintenance Manager.

Start a video at the Ablation HMI showing the power to the cell is currently on. Then continue the video with you opening one of the safety doors. Once the door is open pan over to the HMI and record the power now being shut off.

A place for everything and everything in it's place. Is the Ablation cell following the 5S practices? (Select Yes or No to see more options)

SORT - Eliminate what is not needed. Is there any evidence on the line of tools or items that are not required? Take a photo of any items that should be red tagged or removed from the cell. If there is no issues take photos of the cell showing good SORT practices.

SET IN ORDER - Organize whatever remains by neatly arranging and identifying parts and tools for ease of use. Is the Station organized? Do all tools required for the job have a designated place and is that tool in that place? If there are any items that do not have a place or are not in their place take a photo of them. If not take photos representing good SET IN ORDER practices.

SHINE - Is the work area clean? Is the HMI cabin clean of any dirt and debris? Is the floor around the cell clean with no edge protectors or garbage on the floor? Take a photo for any issue the cell has with SHINE. If there are no issue please take photos representing good SHINE practices.

STANDARDIZE - Schedule regular cleaning and maintenance by conducting daily cleaning of the cell. Is the AM checklist being followed? Take a photo of the AM checklist.

Layered Process audits are designed to verify process conformance. In the Laser cell section of the AM checklist ask the Manufacturing Technician to show you how they validate item k. Once they show you preform the check yourself, validate that all the brushes are in good condition to operate. Where the brushes Ok? Did the Manufacturing Technician inspect the brushes correctly? Take a photo of the brushes condition.

SUSTAIN - Make 5S a way of life by forming the habit of always following the first four S’s. Has the Manufacturing Technician received the 5S training?

Are there any personal items on the line?

We leave the same way we came in. Is the Manufacturing Technician Locking out the cell when going in to the machine? Ask the Manufacturing Technician to demonstrate the LOTO procedure if you have not witnessed them locking out yet.

Inform the Production Supervisor, Production Manager and Plant Manager Immediately. The Line and Audit cannot continue to operate until this is addressed.

During every changeover the Manufacturing Technicians must fully complete a copy of the changeover checklist. Ask the Manufacturing Technician if they can provide the changeover checklist for the last changeover that took place. Is the changeover checklist completed?

Is the changeover checklist that is being used the most current version? Use the below file for reference.

Current version of Ablation line changeover checklist.

Ask the Manufacturing Technician to show you what program is being ran on the HMI. Then ask to see the program currently running on the quality systems (profile and plasma). Does the program being ran on the HMI match the one on the quality systems?

Ask the Manufacturing Technician if they are currently running raw material or reablating NOK material. What type of run is currently occurring?

Take a photo of the plasma upper and lower limits. An example photo is below.

Refer to the SWI attached below on how to setup ablation plasma upper and lower limits. Looking at the current levels would you determine that these are acceptable?

Ask the Manufacturing Technician why the limits were setup incorrectly and why the line was started with these settings.

Current Ablation Plasma SWI

Interview the Manufacturing Technician, ask them the functionality of both the profile and plasma systems and what they believe each system is designed for. Then ask them why it is important to have the correct limitations set for both systems during a production run.

Safety in everything we do. A safe working environment is the most critical aspect of any job. Is the Operator wearing all PPE designated for the safe operation of the ablation line? High visibility vest or uniform, cut resistant sleeves and gloves, earplugs, safety shoes, and safety glasses are all required.

Inform the Production Supervisor before continuing the audit and running the line. This needs to be corrected immediately before any operation can continue.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items b, e, g, and i in Section 4. Break the light curtain of all 4 stacking bays and confirm that the red fault light triggers. Are all stacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the stacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the stacking bays, not all 4.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items b, e, g, and i in Section 4. Break the light curtain of all 4 stacking bays and confirm that the red fault light triggers. Are all stacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the stacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the stacking bays, not all 4.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items b, e, g, and i in Section 4. Break the light curtain of all 4 stacking bays and confirm that the red fault light triggers. Are all stacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the stacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the stacking bays, not all 4.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items b, e, g, and i in Section 4. Break the light curtain of all 4 stacking bays and confirm that the red fault light triggers. Are all stacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the stacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the stacking bays, not all 4.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the hazard been reported, and if possible resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items b, e, g, and i in Section 4. Break the light curtain of all 4 stacking bays and confirm that the red fault light triggers. Are all stacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the stacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the stacking bays, not all 4.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items b, e, g, and i in Section 4. Break the light curtain of all 4 stacking bays and confirm that the red fault light triggers. Are all stacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the stacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the stacking bays, not all 4.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items b, e, g, and i in Section 4. Break the light curtain of all 4 stacking bays and confirm that the red fault light triggers. Are all stacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the stacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the stacking bays, not all 4.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items b, e, g, and i in Section 4. Break the light curtain of all 4 stacking bays and confirm that the red fault light triggers. Are all stacking bay's fault lights working as intended?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the stacking bay having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is only required for one of the stacking bays, not all 4.

A place for everything and everything in it's place. Is the Ablation cell following the 5S practices? (Select Yes or No to see more options)

SORT - Eliminate what is not needed. Is there any evidence on the line of tools or items that are not required? Take a photo of any items that should be red tagged or removed from the cell. If there is no issues take photos of the cell showing good SORT practices.

SET IN ORDER - Organize whatever remains by neatly arranging and identifying parts and tools for ease of use. Is the Station organized? Do all tools required for the job have a designated place and is that tool in that place? If there are any items that do not have a place or are not in their place take a photo of them. If not take photos representing good SET IN ORDER practices.

SHINE - Is the work area clean? Is the HMI cabin clean of any dirt and debris? Is the floor around the cell clean with no edge protectors or garbage on the floor? Take a photo for any issue the cell has with SHINE. If there are no issue please take photos representing good SHINE practices.

STANDARDIZE - Schedule regular cleaning and maintenance by conducting daily cleaning of the cell. Is the AM checklist being followed? Take a photo of the AM checklist.

Layered Process audits are designed to verify process conformance. In the Ablation Dust Collector section of the AM checklist ask the Manufacturing Technician to show you how they validate item a. Once they show you preform the check yourself, validate dry (Ablation) dust collector drum is not full and there is no jam in drain and hose connected to the black drum. Where the drums Ok? Did the Manufacturing Technician inspect the drums correctly? Take a photo of the drums condition.

SUSTAIN - Make 5S a way of life by forming the habit of always following the first four S’s. Has the Manufacturing Technician received the 5S training?

Are there any personal items on the line?

We leave the same way we came in. Is the Manufacturing Technician Locking out the cell when going in to the machine? Ask the Manufacturing Technician to demonstrate the LOTO procedure if you have not witnessed them locking out yet.

Inform the Production Supervisor, Production Manager and Plant Manager Immediately. The Line and Audit cannot continue to operate until this is addressed.

Clear, frequent communication helps people perform their jobs efficiently. Here at AMTB Woodstock we have many forms of communication available to every team member. Does the Manufacturing Technician know the escalation procedure?

The escalation procedure is available in the lines team folder for reference. Please show the Manufacturing Technician the escalation procedure.

Ask the Manufacturing Technician if they are running the line and experience downtime, when should the Manufacturing Technician escalate to their Supervisor?

Explain to the Manufacturing Technician that all downtime must be reported to the Shift Supervisor per the escalation procedure.

Communication between shifts is vital for any troubleshooting or critical items that may not be included in standard work instructions. Ask the Manufacturing Technician to provide 3 different ways that they are able to communicate to either the shift before them or after them.

Safety in everything we do. A safe working environment is the most critical aspect of any job. Is the Operator wearing all PPE designated for the safe operation of the ablation line? High visibility vest or uniform, cut resistant sleeves and gloves, earplugs, safety shoes, and safety glasses are all required.

Inform the Production Supervisor before continuing the audit and running the line. This needs to be corrected immediately before any operation can continue.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items k and l in Section 4. Open the safety door and confirm that the master power at the HMI station drops out. Did the power at the HMI station drop out?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the HMI station having the main power on. Then continue the video showing the safety doors being opened. Once opened pan back over to the HMI to show that there is no longer power to the main HMI.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items k and l in Section 4. Open the safety door and confirm that the master power at the HMI station drops out. Did the power at the HMI station drop out?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the HMI station having the main power on. Then continue the video showing the safety doors being opened. Once opened pan back over to the HMI to show that there is no longer power to the main HMI.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items k and l in Section 4. Open the safety door and confirm that the master power at the HMI station drops out. Did the power at the HMI station drop out?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the HMI station having the main power on. Then continue the video showing the safety doors being opened. Once opened pan back over to the HMI to show that there is no longer power to the main HMI.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items k and l in Section 4. Open the safety door and confirm that the master power at the HMI station drops out. Did the power at the HMI station drop out?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the HMI station having the main power on. Then continue the video showing the safety doors being opened. Once opened pan back over to the HMI to show that there is no longer power to the main HMI.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the hazard been reported, and if possible resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items k and l in Section 4. Open the safety door and confirm that the master power at the HMI station drops out. Did the power at the HMI station drop out?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the HMI station having the main power on. Then continue the video showing the safety doors being opened. Once opened pan back over to the HMI to show that there is no longer power to the main HMI.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items k and l in Section 4. Open the safety door and confirm that the master power at the HMI station drops out. Did the power at the HMI station drop out?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the HMI station having the main power on. Then continue the video showing the safety doors being opened. Once opened pan back over to the HMI to show that there is no longer power to the main HMI.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items k and l in Section 4. Open the safety door and confirm that the master power at the HMI station drops out. Did the power at the HMI station drop out?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the HMI station having the main power on. Then continue the video showing the safety doors being opened. Once opened pan back over to the HMI to show that there is no longer power to the main HMI.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items k and l in Section 4. Open the safety door and confirm that the master power at the HMI station drops out. Did the power at the HMI station drop out?

Inform the Production Supervisor and Maintenance Manager.

Take a video of the HMI station having the main power on. Then continue the video showing the safety doors being opened. Once opened pan back over to the HMI to show that there is no longer power to the main HMI.

A place for everything and everything in it's place. Is the Ablation cell following the 5S practices? (Select Yes or No to see more options)

SORT - Eliminate what is not needed. Is there any evidence on the line of tools or items that are not required? Take a photo of any items that should be red tagged or removed from the cell. If there is no issues take photos of the cell showing good SORT practices.

SET IN ORDER - Organize whatever remains by neatly arranging and identifying parts and tools for ease of use. Is the Station organized? Do all tools required for the job have a designated place and is that tool in that place? If there are any items that do not have a place or are not in their place take a photo of them. If not take photos representing good SET IN ORDER practices.

SHINE - Is the work area clean? Is the HMI cabin clean of any dirt and debris? Is the floor around the cell clean with no edge protectors or garbage on the floor? Take a photo for any issue the cell has with SHINE. If there are no issue please take photos representing good SHINE practices.

STANDARDIZE - Schedule regular cleaning and maintenance by conducting daily cleaning of the cell. Is the AM checklist being followed? Take a photo of the AM checklist.

Layered Process audits are designed to verify process conformance. In the Main Air Supply section of the AM checklist ask the Manufacturing Technician to show you how they validate item a. Once they show you preform the check yourself, verify main air supply pressure. Did the main air supply have sufficient pressure (0.21 - 0.24 Mpa)? Take a photo of the pressure.

SUSTAIN - Make 5S a way of life by forming the habit of always following the first four S’s. Has the Manufacturing Technician received the 5S training?

Are there any personal items on the line?

We leave the same way we came in. Is the Manufacturing Technician Locking out the cell when going in to the machine? Ask the Manufacturing Technician to demonstrate the LOTO procedure if you have not witnessed them locking out yet.

Inform the Production Supervisor, Production Manager and Plant Manager Immediately. The Line and Audit cannot continue to operate until this is addressed.

Funnel Cloud is a multi-functional reporting system that is currently installed on this line. Is the Manufacturing technician able to locate the FunnelCloud SWI on IQS?

FunnelCloud SWI's can be found using the following documnet ID's 09955-CAD, 09959-CAD, and 09960-CAD. Locate these documents on IQS and present them to the operator.

Has the downtime for the machine been recorded? Take a photo of the funnel cloud report located on the large TV above the HMI.

Ask the Manufacturing Technician why the downtime has not been recorded yet.

Has all downtime been classified? Take a photo of the classified downtime.

Ask the Manufacturing Technician why there is unclassified downtime.

Accurate scrap reporting is essential to an accurate inventory value. Ask the Manufacturing technician how many scrap parts they have produced this run. Does the scrap reported on the FunnelCloud system match what was reported?

Ask the Manufacturing Technician about the discrepancy and why they believe the two number are not matching.

Go to the machine activity section on the left hand of the screen, then select the unclassified option in the top right hand corner.

Which Shift are you Auditing on

Safety in everything we do. A safe working environment is the most critical aspect of any job. Is the Operator wearing all PPE designated for the safe operation of the ablation line? High visibility vest or uniform, cut resistant sleeves and gloves, earplugs, safety shoes, and safety glasses are all required.

Inform the Production Supervisor before continuing the audit and running the line. This needs to be corrected immediately before any operation can continue.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the above issue been resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, and f in Section 1. Follow the "Key Points" section for each item in order to verify process conformance.

Inform the Production Supervisor and Maintenance Manager.

Take a video of the DUNI bay 1 having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is to verify process conformance for item b on the safety checklist.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, and f in Section 1. Follow the "Key Points" section for each item in order to verify process conformance.

Inform the Production Supervisor and Maintenance Manager.

Take a video of the DUNI bay 1 having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is to verify process conformance for item b on the safety checklist.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, and f in Section 1. Follow the "Key Points" section for each item in order to verify process conformance.

Inform the Production Supervisor and Maintenance Manager.

Take a video of the DUNI bay 1 having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is to verify process conformance for item b on the safety checklist.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, and f in Section 1. Follow the "Key Points" section for each item in order to verify process conformance.

Inform the Production Supervisor and Maintenance Manager.

Take a video of the DUNI bay 1 having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is to verify process conformance for item b on the safety checklist.

Take a survey around the ablation cell, including all surrounding areas are there any potential safety risks?

Pause the audit and create a Spot the Hazzard. Work with the Manufacturing Technician and Production Supervisor to resolve the issue before continuing.

Has the hazard been reported, and if possible resolved?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, and f in Section 1. Follow the "Key Points" section for each item in order to verify process conformance.

Inform the Production Supervisor and Maintenance Manager.

Take a video of the DUNI bay 1 having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is to verify process conformance for item b on the safety checklist.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, and f in Section 1. Follow the "Key Points" section for each item in order to verify process conformance.

Inform the Production Supervisor and Maintenance Manager.

Take a video of the DUNI bay 1 having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is to verify process conformance for item b on the safety checklist.

At the beginning of the work week a safety checklist must be completed before the line can be operated. Ask the Manufacturing Technician to locate this checklist, has the checklist been completed?

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, and f in Section 1. Follow the "Key Points" section for each item in order to verify process conformance.

Inform the Production Supervisor and Maintenance Manager.

Take a video of the DUNI bay 1 having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is to verify process conformance for item b on the safety checklist.

Pause the audit and ask the Manufacturing technician to complete a pre shift safety checklist. The line cannot be operated without a filled in pre shift safety checklist completed.

Has the Manufacturing Technician completed the Safety checklist?

Escalate the condition to upper management. Be sure to explain why this issue has not been resolved. The audit and the operation of the line cannot continue when anyone's well being are at risk.

Layered Process audits are designed to verify process conformance. In this audit please verify items a, b, c, and f in Section 1. Follow the "Key Points" section for each item in order to verify process conformance.

Inform the Production Supervisor and Maintenance Manager.

Take a video of the DUNI bay 1 having a green light indicating the line is ready to run. Then proceed to break the light curtain and continue to take a video of the fault light changing to red. This is to verify process conformance for item b on the safety checklist.

A place for everything and everything in it's place. Is the Ablation cell following the 5S practices? (Select Yes or No to see more options)

SORT - Eliminate what is not needed. Is there any evidence on the line of tools or items that are not required? Take a photo of any items that should be red tagged or removed from the cell. If there is no issues take photos of the cell showing good SORT practices.

SET IN ORDER - Organize whatever remains by neatly arranging and identifying parts and tools for ease of use. Is the Station organized? Do all tools required for the job have a designated place and is that tool in that place? If there are any items that do not have a place or are not in their place take a photo of them. If not take photos representing good SET IN ORDER practices.

SHINE - Is the work area clean? Is the HMI cabin clean of any dirt and debris? Is the floor around the cell clean with no edge protectors or garbage on the floor? Take a photo for any issue the cell has with SHINE. If there are no issue please take photos representing good SHINE practices.

STANDARDIZE - Schedule regular cleaning and maintenance by conducting daily cleaning of the cell. Is the AM checklist being followed? Take a photo of the AM checklist.

Layered Process audits are designed to verify process conformance. In the Laser cell section of the AM checklist ask the Manufacturing Technician to show you how they validate item c. Once they demonstrate their technique preform the check yourself, Pull out lens holder on Souvis upper and lower camera. Make sure holder is not damaged and ensure the lens is free from dust and debris. Take a photo of the lens condition, then put the holder and lens back into the camera, ensuring that both are fully seated and secure. Was the Lens free of dust and debris?