PROCESS AUDIT CHECK SHEET CUM REPORT

Format no: COM-CK-01, Rev 1A, and Date 01.10.11

Department / section: Prod. / IMG Date of Audit:

Process Name:Blow Molding Current Audit Score: 72%

Name & Sign. Of Auditee:Mr. Previous Audit Score: NIL

Name & Sign. Of Auditor: Mr.

Requirements SCORE Auditors Notes /
Objective Evidence
0 1 2 3
A. Personnel / Qualification
1. Awareness about responsibility & authority Operator, Production supervisor & Quality
for monitoring the product / process quality? Inspector are aware about their roles and
Operator responsibility.
Production supervisor
Quality inspector
2. Suitability of employees to perform the Ok
required tasks

3. Availability of skill records Skill matrix record not availabled.

Operator
Production supervisor
Quality inspector

4. Availability of multi-skill personnel No evidence found of multi skill data.

5. Awareness about special characteristics? Operator not aware about special characteristics.
Operator
Production supervisor
Quality inspector

6. Awareness about impact on customer Awareness availabled.

(internal & external) due to non-conformity
of their operation?
Operator
Production supervisor
Quality inspector
7. Use of personnel protective equipment as Safety shoes not wear by operator.
detailed in the Work Instructions? Lint free cotton gloves not availabled.

B. Production Materials /
Equipment/Process
8. Process Capability SPC data availabled.

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 Requirements SCORE Auditors Notes /
Objective Evidence
0 1 2 3
9. Process validation Record not availabled.

10. Adherence of maintenance plan of Adhered.

equipment

11. Fulfillment of Product Specific quality Ok

requirements with the existing production
equipment / tools?

12. Monitoring of process parameters Process parameter data not availabled in desired
format.
SMP not freezed.SMP Head temp.ZONE 8-198 &
Actual temp.180

13. Monitoring of product characteristics FPA/LPA report availabled.

14. Suitability of work stations? Work instruction availabled.But not update.

Doc-no.MTC-PRD-EIS-56 Check point no-2
UPVC SOLVENT ON THE GROMMET W.I. BUT
NOT APPLICABLE

15. Suitability of inspection stations? Availabled.

16. Are monitoring & measurement devices Calibration plan available.FCO-SHE-FM-12

calibrated & kept at designated location? Digital Vernier Caliper VC-06 not calibrated (due
date-26.11.2015)

17. Availability of the relevant details in the Production documents availbled but SMP not
production documents? freezed.

18. Availability of the relevant details in the Quality documents availabed at desired locations
Quality Assurance documents? like FPA/LPA Sheet and In-process check sheet.

19. Availability of necessary tools for process Availabled.

adjustments?

20. Is the set up approval at the start of No data availabled.

production followed?

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 Requirements SCORE Auditors Notes /
Objective Evidence
0 1 2 3
21. Are process adjustment details as well as Not applicable till audit.
deviations recorded?

22. Are the required corrective actions carried Data availabled.

out on schedule and checked for
effectiveness?

23. Is applicable SPC tool being applied & Ok

monitored at defined frequency as per
Control Plan?

24. Is Cpk being maintained more than or equal CpK- 2.78

to Product Approval Process?

25. Is productivity being achieved as planned? OK

26. Are rework instructions available at Rework work instruction availabled.

appropriate locations?

C. Transport / Parts Handling

27. Are products / components appropriately Washer system kept in trolley in arrange order
stored?

28. Are transport means / packing equipment OK

tuned to the special properties of the
product / components?

29. Are rejects, reworks, internal residues and OK

adjustment parts strictly separated and
identified?

30. Are labeling / identification provided on the OK

products & at the location? As per
procedure to avoid mix-ups & ensuring
traceability?

31. Are labeling/ identification adequate to OK

avoid mix-ups & ensuring traceability?

32. Are condition of WIP boxes and trolleys OK

being maintained adequately?

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 Requirements SCORE Auditors Notes /
Objective Evidence
0 1 2 3

D. Fault Analysis / Corrective Action /

Continual Improvement
33. Are quality and process data recorded Quality documents available at desired locations
complete and ready to be evaluated? like FPA/LPA Sheet and In-process check sheet.

34. Are the causes of product and process non- Data not available from Nov and Dec month.
conformances analyzed and the corrective
actions checked for their effectiveness?

35. Are target parameters (rework, scrap) Data not availabled

available for product and process and is
their compliance monitored?

Evaluation process Audit Audit Summary:

results:
Points Assessment

3 Requirements fully met

Requirements mainly (3/4

part ) met, minor deviation
2
present (Consider as minor
NC)
Requirements partially met,
1 major deviation present
(Consider as major NC)
Requirements not met,
0 serious deviations present
(Consider as major NC)

Audit Rating Audit

Criteria Consequences after manufacturing process audit done
result
Sustain the present level and focus on further improvement through
Rating "A" > 92% Very Good Poke-Yoke, Low cost automation, process optimization and shop
floor management.
Corrective Action plan need to be taken with in15 Days and
Rating "B" 82 ~ 91% Good Subsequent re-audit is required.

Immediate containment required and Corrective Action plan need to

Rating "C" 70~ 81% Average be taken with in15 Days and Subsequent re-audit is required.

Needs extra Management focus to improve the process and

Rating "D" < 70% Poor required extra checks to avoid any flow out.
Immediate containment required and Corrective Action plan need to
be taken with in15 Days and Subsequent re-audit is required.

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