Q-System audit result

CONTENTS
1

Process audit overall

2 3 4 5 6

Process audit list : 6 Tool Process audit list : Condition control Process Audit List : Outgoing assurance /CTQ Control Process audit list : T5S NC point of Process Audit

Auditor : Atul Arora

08.11.10

C&M Go

In charge

approval

Vendor) Q-System audit result

C&M Biz. Team
Vendor Auditor Taehwa Ent. India Pvt. Ltd. Motor Line Atul Arora Audit dt. Attended by from Taehwa Obtained mark 5.1
8 8

approval

02nd Nov,2010 Mr. M.K Singh, Mr. Ravi

Obtained mark 99

Grade A, B, C, D

category

Item
Quality meeting OS&D control Sequential inspection Key process control T/Check Q-audit Total Man Machine /tools Materials

Allotted mark
9

Opinion about overall audit result

[Good points) Time Check Customer Critical Process Control Incoming inspection started
[Major problems] Review Mgmt poor - No weekly Q review - No Monthly Q-Review Supplier control Weak Process Control not OK LG Return Rej Analysis Gauge R&R Plan not available Machine Maint./ Tooling mgmt not OK.

5.8 6.3

6-tools

5.9
9 8 50 5 5 5 10 5

6.8 4.0
33.9

3.5 3.0 3.3 6.4 3.3 Previous Audit history

Audit dt. 27th July 10

Mark 55

Grade D

Audit dt.

Mark

Grade

4 M control

Method Information of 4 M changes Total

30 20 50

19.5 11.6 34

Outgoing quality assurance /CTQ control T5S

Grade (Grade A : 150~131 points, Grade B : 130~111 marks, Grade C : 110~91 mark, Grade D : lower than 90) F/up of result (Higher than Grade B : Pass, to publish NCR report, Lower than Grade C : re-audit and to link to biz wrap up???)

1 / 7

Audit check list 6 tools

Item
Detailed audit item 1) Quality meeting (9 points) 1) Is daily quality meeting being held? 2) Is daily quality meeting record being maintained properly? 3) Is Quality index being recorded in the quality status board? - Part RTN defect rate (monthly), process defect rate (daily, monthly) 4) Is weekly quality improvement meeting being held? 5

Excellent -- Bad
4 3 2 1

calculatio n

Obtained mark
. 1)

Opinion from auditor

2) xi 1.8 n 5.1

Weekly and monthly quality meeting not being held. Action Plan not available for weekly Quality Meeting

5) Is monthly review meeting being done?

6) Is F/Up for the decided item being done 2) OS&D control (8 points) 1) Is RTN, IQC reject, and claim received set being recovered immediately? 2) Is NG set being displayed for a specified period? 3) Is defect phenomena being taught to operator? (Is operator aware about NG?) 4) Is countermeasure for the NC item being replied in time? 5) Is the detail regarding 2nd vendor being F/B and is its countermeasure being followed? 1) Is self/sequential inspection item being set and followed? 3) Sequential inspection 2) Is NG set being recognized by putting tag or marking with marker? 3) Is NG set being kept in defect box? 4) Is operator wise record being maintained? 5) Is countermeasure for the defect been set?

1) 2)

Second vendor follow-up not available Improvement action plan for supplier improvement not available

- Return set control

5.8
xi 1.6 n

1) Overall, sequential inspection activity is lacking. 2) Operator wise self & sequential record not maintained

6.3

xi 1.9 n

6) Is prize being awarded as per the achievement of each operator?

Profitable Market Share Growth

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Audit C/List 6 Tools

Excellent -- Bad Item 4) Key process control (8 points) Detailed audit item 1) Has key process sign board been attached on the problem process? 2) Is check sheet being made and is supervisor checking the performance? 3) Is key process control liked with history control and improvement activity? 5 4 3 2 1

calculatio n

Obtained mark

Opinion from auditor 1) History control with improvement plan

xi n 2.3

5.9

xi
n 1.8

1) Is T/Check being carried out time wise (initial, mid, final)? 2) Has surface plate, measuring equipment, jig, and check sheet etc. been displayed? 3) Is actual set being kept as first set, mid production set, and final set wise? 4) Is line leader, production head checking whether T/Check is being done? 5) Is NG immediately corrected and its improvement activity being carried out? 1) Is Q-audit system been assigned? 3) Q-Audit System 2) Is A-audit being carried out on a monthly basis? 3) Is checking being carried out as per Check standard? 4) Is Q-Audit evaluation sheet being made? 5) Is improvement activity being carried out for the NC item? 6) Is audit result (mark, NC point) being displayed and shared?

1) NG Item Action Plan not available

5) T/Check

6.8

4.0
xi n 1.6

3) Q-system Audit Action Plan not available Audit grade comparison not available

Profitable Market Share Growth

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Audit C/List - 4 M condition control

Excellent -- Bad 5 1) Man (5 marks) 1) Is QC organization made and being operated (see organization chart) ? 2) Is training plan been set and is training given to all the employee? 3) Is operator aware about CTQ, T/Check, sequential inspection for his process? (more than 3 operators) 4) Is OJT, necessary training given to operator if operator in process changed? 2) Equipment /tools (5 marks) 1) Is history card for production equipment, tools available and newly making, repair, modification, and shifting history being recorded? 2) Is operation std. been set and displayed in major production equipment and is checking being done as per checking std.? 3) Is equipment running condition been complied and isnt worker change the condition arbitrarily? (C-gun, to assign in charge, and to mark of no arbitral change) 4) Is tool control condition after production OK? (To check whether tool condition is being checked, cleaning, and keeping method) 1) Is raw materials report (std.) available? 3) Materials (5 marks) 4 3 2 1 calculation Obtain ed mark

Item

Detailed audit item

Opinion from auditor

xi n 1

1) No training plan for executive level

3.5

1) 2) Overall Equipment control lacking Preventive maintenance check point & check sheet to be implemented

xi n 1

3.0

3.3
xi n 1

2) Is incoming low wise materials report (mill sheet) been obtained and controlled?
3) Is materials incoming and outgoing log book being controlled? 4) Is tracing system available in case there is problem in raw materials?

Profitable Market Share Growth

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Audit C/List - 4 M control

Item Detailed audit item
5 4) Method (10 marks) 1) Is QC, 4M control chart been made? 2) Is working standard been displayed in the process? (more than 80%) 3) Is working std. and work matching and is working condition being complied (to check key process) 4) Is changed contents of working method and inspection method been revised and controlled (process chart, standard) in chase working method and inspection method are changed? 5) Is drawing from customer been entered in drawing log book and is its history being controlled and is its latest version being marked? 6)Is specification log book being recorded and is its contents being arranged in drawing and is it being feed/back to related dept? 7) Is process audit and vendor audit report for 2 nd vendor been prepared and is periodical audit being carried out? Excellent -- Bad 4 3 2 1

Calculation

Obtain ed mark

Opinion from auditor

1) Motor runout check point put in drg but not added in Patrol inspection check sheet 2) There is no audit report for the 2nd vendor.

xi 2.0

6.4

3.3
xi
n 1

8) Is incoming quality inspection and history control for the 2nd vendor being carried out?
9) Is necessary measuring instrument available and calibration being carried out periodically? (Measuring equipment history card) 1) Is raw materials report (std.) available? 3) Materials (5 marks)

2) Is incoming low wise materials report (mill sheet) been obtained and controlled?
3) Is materials incoming and outgoing log book being controlled? 4) Is tracing system available in case there is problem in raw materials?

Profitable Market Share Growth

5 / 7

Audit C/List Outgoing quality assurance/CTQ control

Excellent -- Bad 5 1) Is separate OQC inspector been assigned in QC organization chart and is it being operated? Outgoing quality assurance (20 marks) 2) Is item wise OQC inspection item been assigned and is inspection history card available? 3) Is OQC inspection history being controlled per every lot? (Control with inspection report & system) 4) Is OQC inspector controlling the quality problem and spec. changes history? 4 3 2 1 Obtain ed mark

Item

Detailed audit item

Calculation

Opinion from auditor

xi n 4

1 ) Gauge R&R Plan not available 2) CTP Item not selected 3) For critical processes like Crimping ht CTQ value not monitored , neither Z value trend made available.

5) Is Lot tracing possible by classifying outgoing lot wise production date?

6) Is identification card attaching for the inspection ready /inspection completion/ NG item been classified? 7) Is measurement and item wise possible measuring instrument been equipped as per outgoing inspection item? 8) Is periodical gage R&R being carried out with customer for the outgoing item? 9) Is important quality been selected as CTQ item and is CTQ item adjustment history been controlled on a monthly basis? 10) Is CTP control item been selected for the satisfaction of customer? 11) Is improvement activity being carried out during process capa. analysis and when target value (Z) is not achieved?

11.6

Profitable Market Share Growth

6 / 7

 C/List T5S
Audit item 5S Arrangement and organization 10 Grade E Unnecessary item, NG item, left over from production are left at site without marking 2 Grade D Unnecessary item being handled without any plan Part mixed stacked. 4 Grade C Temporary disposal place assigned, periodically disposed Depot area control 6 Grade B Whenever unnecessary item is found, it is disposed as per rule Standard inventory /stock quantity is being complied 8 Equipment cleaning is being done periodically Equipment in charge posted and operated 8 Right container, right quantity is being complied and kept at right location 8 The system in which anyone can find out problem and solve Abnormal condition is controlled cumulative way and linked to improvement 8 Time wise target and result, line loss status is being marked. Status board is being maintained item wise and element wise. 10 Grade A Basic system to prevent defect recurrence is available Linked to decreases in inventory/ stock 10 Obtained mark Opinion from Auditor

8 points

Cleaning and cleanness 10

Floor, wall not cleaned and dirty. 2

Cleaning tools control, drinking water control, dressing place control OK Floor, wall, and ceiling is clean 4 Having concept of gangway and having simple concept of right location level. 4 The system by which operator can not report by self when any problem is occurred. The condition in which only related personal handles. 4 Production status, loss status not being controlled Status board control lacking 1

Cleaning area, in charge frequency clear. Corner, drinking water, dressing area 6 Controlling the system by which location, item, and amount can be figured out. 6 The system by which operator can report by self when any problem is occurred. Controlling done by linking to related dept. 6 Production target vs. result control Cleanness of Status board so so 6

Habituated cleaning and maintaining cleanness Basic improvement activity is being done 6 points to prevent contamination The system by which 3 R is being complied. Bin /pallet /container 10 Problem condition is being controlled in the form of data, systemization 10 8 points

Machine owner not decide for 5S

3R

Right location, right quantity, Right container 10

Inventory stacked on gangway, floor. Part, tools left on the floor 2 The system by which normal and abnormal can not be figured out. 2

Location not defined for rework material 6 points

Visible manageme nt

Finding out abnormality, handling the abnormality 10

Status board control 10

The system by which production status, loss can not be figured out. 2

Production status and distribution status of loss can be seen immediately Maintaining 6 points cleanness of data sheet in status board 10

Item wise detail with idle time not monitored on display board

Total 34 marks

Profitable Market Share Growth

7 / 7