Audit Findings Workshop

Analyze the situation and write your finding in every situation. 1. As you audit the Quality Control Department Head, he explains, Customers complaints are entertained in my office. Records are kept in my cabinet which is in front of me. He stood up and took the records from the cabinet nd and gave the records to you. You have browsed the complaints records and took the 2 complaint from the top of the record. The complaint was about the miscount of belts. It read as follows, Dear ABP, Last Saturday we received your shipment about the belts we have ordered. As we checked the quantity, we found out that 50 pieces of belts are lacking. We ordered 1200 pieces and we received only 1150 pieces. Please send the balance immediately. We shall expect the arrival of the balance tomorrow afternoon. NC 2. During the audit of the Quality Control Department, you have read in the WI 010 that Those batches which do not meet the requirements shall be tagged by the inspector with the red ON HOLD tag. You requested the QC inspector to bring you to the reject batches. When you were near the reject batches, you were looking for the red tag and you cannot find any. You asked the inspector, Where is the red tag? The inspector replied, Nalimutan ko pong lagyan. 3. After doing the entire introduction to the Head of the Warehouse, you started the audit at the Raw Materials Storeroom. You have seen the pile of bags of carbon inside the Storeroom. You read the labels written on one of the bags, it reads as, To be stacked not more than 6 high. You also noticed the arrow on the bag. You move one step closer and counted the stacking pile. You have counted 5 bags in the pile and notices that the arrows of the three bags in the pile are pointing to your left. 4. As you continued the audit in the Warehouse, the Warehouse staff was very proud to show to you their computerized inventory system. She explained, It makes it easier for the warehouse personnel to locate every item inside the Storeroom. You can search per brand, per part name, or part number, explained further by the staff. They are even classified whether fast moving, slow moving or obsolete items. Confident on her system, the staff asked, Do you want to try it? So as not to disappoint the staff, you took the mouse and click it to Brand, and then, Name. Then, you typed, battery. Appearing on the screen are the Quantity and Location. You read 2 pieces of Motolite battery and Location is SDW-005H. You requested the staff to bring you to the batteries. The staff politely showed you the way going to the batteries. As you approached the batteries, you have seen two batteries placed neatly on the rack. You asked her where is the SDW-005H placed on the rack. She began to get nervous for she cannot find the mark. What she saw was SDW-006H.

5. The Maintenance Manager was very proud to tour you around their workplace. He explained, The expensive spares and other items are kept in that cabinet which is normally padlocked. You, the auditor, have made a body movement to signal that you wish to be near the mentioned cabinet. As you walk near the cabinet, the manager continued, The noncritical items are kept downstairs. The entire storeroom downstairs is fenced and it is also locked when our storekeeper is not around. You said, Very good. Lets see your other items downstairs. As you turned your back, you saw some items adjacent to the door. You asked, What are these items. The Manager quickly replied, Ah yes. These are used items. Some are still useful and some are not. You quickly asked, I cannot see any marks which are useful and not. Can you help me identify which is which? The Manager now somehow rattled, So-so-sorry, I cannot. 6. We treat Management Review as our monthly Management Meeting. The participants are the Department Heads and up levels, explained by the President during his audit. Anyways, whatever we discussed during our Management Meeting are the so-called Review Inputs of ISO. Basically, we discussed what is happening in the entire plant --- operational requirements, customers complaints, employees concerns, problems, measures, improvements, etc., the President added. After hearing the explanation of the President, you read the minutes of the last months meeting. As you read the minutes, you have encountered the sentence, The Production Yield for both Mill Department and Belt Department were not met last month. You requested the President to clarify about this ---- what does it mean, what decisions and actions have been taken to rectify this matter. The President gladly clarified this to you.

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7. You went to the Compounding area were the different materials are mixed. You have noticed that the operator was using a weighing scale. You asked the operator, Papaano mo alam na tama ang sukat na ibinibigay sa iyo ng iyong timbangan? The operator answered, A, madali lang po iyan. Tinitingnan ko po sa likod kung itoy calibrated o hindi. May label pong inilalagay iyong aming taga-calibrate sa likod. The operator showed the label to you and you made a follow-up question, Sino po ang nag-ka-calibrate nito? Iyong pong aming mekaniko, the operator replied. 8. During the Belt Department Audit, you noticed the different samples of rejects of belts posted on one of the walls of the Finishing Area. You asked the Supervisor whom you are auditing regarding its purpose. This serves as a guide to our Finishers so as to ensure that rejects are properly identified, replied the engineer. Is this a controlled guide?, you immediately asked. No! The controlled document is in our Procedure Manual entitled Belt Rejects, ABP-WS-013, answered by the Supervisor. Would you know if this will be an obsolete guide? as you pointed to the guide. Confidently, the Supervisor replied, Yes! I believe so. I am the one in charge of revising our documents in this area. So, if ever the relevant document will be revised, say Belt Rejects, ABP-WS-013, I immediately change and update this posted guide. 9. You are about to go upstairs to audit the Belt Department Head when you saw one employee getting materials along the walkway leading to the stairs. You stopped and asked the employee, Ano po iyang parang spongha na iyan? Raw rubber po ito, answered by the employee. Papaano po ninyo alam na okay po ang rubber na iyan, you asked further. Mula po nang magsimula ako rito, 7 taon na po ako rito, lagi po ako ritong kumukuha ng raw rubber na gagamitin ko, politely replied by the employee. O sige po. Maraming salamat po, as you pointed yourself going upstairs. 10. As you looked at the Belt Department Report for the month of July, you asked the head, May I know the meaning of each title in the column? Oh, yes, sure, answered by the Head. This one tells the number of output per month. This one tells the minimum and maximum of the specs of each batch. This one tells the cpk. What is Cpk? asked by the auditor. Honestly, I dont know. When we were starting this company, the Japanese told us to compute this and include it in our report. 11. Thank you very much, the auditor said. It seems your hiring procedure is very clear. Now, let me deal on how you train your employees. Can you kindly explain to me your training process? asked by the auditor. The Personnel Manager quickly replied, We train our employees through in-house programs or by sending them outside. In general, the department head sets all the logistics of the training from the resource person, the participants, and venue and other materials needed in the training. After the training, we received the attendance sheet. Once we receive the attendance sheet, we record the training attended to the individual training records of the employees. Thats how we do training here, explain briefly by the Personnel Manager and he gave Training Procedure, TR-PR-010 to the auditor. The auditor browsed the procedure and found out that what have been said briefly was correct. The auditor said, I heard from the QMR that almost all of the employees have attended the ISO Awareness Program. Were you able to attend such program? Yes, I attended the Management Team and Core Team ISO Awareness Program It was a one-day session, confidently answered by the Personnel Manager. May I see your own Training Record? requested by the auditor. The Personnel Manager requested the Personnel Supervisor to get his own Training Record. Then, the auditor read it. It was not indicated in the record that the Personnel Manager attended the ISO Awareness Program.

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