PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
AUDIT DATE :28.08.15
DEPARTMENT:PRODUCTION
PROCESS: ALL PROCESS
PREVIOUS AUDIT DATE:NA
AUDIT NUMBER:PAR - 002
AUDITOR:KUMARAVEL
AUDITEE(S):INBA,NARAYANAN,GANAIYAH,MICHAEL,VIGNESH,
NAVEEN,RAJA,NATIYA
GENERAL FINDINGS
Raw material receipt, storage and
issue:
Observations
Responsible
Person
Target Date
Status
Receiving
inspection
mentioned in
Lot
management
sheet, but not
included in the
QC process
check sheet.
Dill raj
30.09.15
Material grade
and material
details not
known to PPC
person.
Dill raj
30.09.15
Use me first
tag for FIFO
followed, it is a
good practice,
but not
documented.
Dill raj
30.09.15
Identification
tag system to
Dill raj
30.09.15
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
monitor the rod
bundle status, it
is also good
system, but not
included in
process.
Production plan
not updated
during the
audit.
Dill raj
30.09.15
Raw material
quantity
mismatch,10 kg less
than the purchased
quantity. Heat
number 91446,
received on 25th
Aug. invoice
quantity is 6760 kg,
but actual measured
at our end was
6750.kg.no
information and
process to share this
issue to supplier.
Dill raj
30.09.15
For production
lot issued in KG
not verified
according to the
actual bars
issued. Also for
each bar, how
many parts can
Dill raj
30.09.15
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
produced is
arrived, but not
verified and no
such process
Receiving
inspection
judgement not
given in all lot
management
sheets.
kumar
19.09.15
Same lot
number
20150825-001
is used for
many batches.
This is not
correct,
different
numbers need
to be given like
001,002,003
etc.
Dill raj
30.09.15
Number of rods
issued to
production is
counted, but
number of end
bits not
counted,
weighing only
done, process
need to be
changed,
Dill raj
30.09.15
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
otherwise
chance of
putting setting
rejections with
end bar. (If 20
rods issued,
then 20x2 =40
end bits to be
counted and
verified at the
end of the day).
Overall man things followed, but not documented and
displayed as
procedures.
Sawing and Chamfering:
Observations
Before
chamfering
area, bins area
placed for
temporary
storage, not
identified only
paint markings
available.
Measuring
instruments
used in
Responsible
Person
Target Date
Status
Mani
19.09.15
Kumar
19.09.15
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
chamfering area
found without
calibration
sticker and
operator
doesnt aware
about the
calibration of
instruments.
For a single rod
how much parts
can be
produced and
quantity
management is
not listed and
operator
unaware about
this process.
Operator
checking F/M/L
and giving
result as ok for
Charge number
and Material.
But two
operators dont
know what
charge is and
what material
is.
Skill matrix
need to be
updated. Old
one available.
Chamfer jig list
Mani
19.09.15
Mani
19.09.15
Mani
19.09.15
Muthu
19.09.15
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
with manually
corrected specs
available and
also stick on the
chamfering
machine.
Prepared and
approved sign
not available.
Heat number
location
availability in
the rods,
unaware to the
operator.
Colour bin
identification
unaware to the
operators.
Operation
manual
numbers were
not matching
with QC process
check sheets.
Mani
19.09.15
Mani
19.09.15
Muthu
19.09.15
Bonde:
Observations
Operator having
Responsible
Person
Mani
Target Date
30.09.15
Status
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
7 months
experience and
handling
machines
individually
cannot be a
under training
person. Skill
matrix need to
be revised.
Lot
management
hanging board
system followed
for traceability,
which was not
included in the
QC process
check sheet or
any other
document.
Operating
manual
mentioned as
KPI/PROD/WI/00
5 in QC process
check sheet not
available in
bonde area.
In sulphuric acid
bond rising
point
management
sheet point
mentioned as
10-19, but as
Muthu
30.09.15
Muthu
30.09.15
Muthu
19.09.15
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
per QC process
check sheet it is
9.5-19, need to
be changed.
In that
operating
manual
available for
points checking
level of
measurement
and burette
used for that
purpose not
included.
MSDS available
found without
prepared and
approval sign.
Also in hazard
column wrongly
mentioned as
land
contamination,
we need to
mention
because of each
chemical what
are the hazards
we will face, not
how to dispose
those
chemicals.
Bonde operation
standard
KPI/PRD/F/11
Muthu
30.09.15
Muthu
30.09.15
Muthu
30.09.15
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
displayed not
mentioned in
QC process
check sheet.
Operating
manual
prepared for
degreasing
water bread
chemical mixing
is not included
in QC process
check sheet.
Muthu
30.09.15
Press:
Observations
Operators who
are well trained
should not be at
the level of
work under
supervision.
Need to be
changed.
Operator
Moganaranga
left the job still
available in the
Skill matrix, to
be removed.
20 numbers
once cleaning
not
Responsible
Person
Target Date
Status
Mani
30.09.15
Mani
30.09.15
Muthu
30.09.15
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
documented.
which is also not
documented.
Hydraulic press
die list available
without
documents
number,
prepared,
approved sign.
Setting
conditions
available in the
operation
standard
unavailable to
the operator,
but they are
simply putting
ok in QC
process check
sheet.
Sawing and
chamfering
machine
Operator who
will also run the
press machine,
skill matrix not
updated.
Muthu
30.09.15
Mani
30.09.15
Mani
30.09.15
Weight and Visual inspection:
Observations
Responsible
Person
Target Date
Status
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
F/M/L check by QA
inspector not
included in the QC
process check sheet.
Inspection manual
for weight and visual
inspection not
available
Weighing machine
used in
chamfering
machine not
calibrated.
After introducing
new weighing
machine,
validation not
done and records
not available.
Weight machine
calibration display
not available
kumar
30.09.15
Kumar
30.09.15
kumar
30.09.15
Kumar
30.09.15
kumar
30.09.15
Final inspection and Dispatch
inspection:
Observations
Responsible
Person
Target Date
Status
Final inspection
procedure not
available
Kumar
25.09.15
Lot quantity
updated in N5
register and actual
Gopal
30.09.15
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
lot quantity not
matching.
Defect samples
display in the shop
floor is not
properly available
and visible.
Kumar
30.09.15
Dispatch:
Observations
Responsible
Person
Target Date
Status
FIFO not followed
properly while
moving Forged parts
to FG.
Dispatch procedure
not available and
displayed, also to be
included in the QC
process check sheet.
Packing checklist
to be followed.
Dilli
30.09.15
Dilli
30.09.15
Dilli
30.09.15
Packing standard
not available, not
displayed and PPC
person unaware
about that.
Dilli
30.09.15
Dilli
30.09.15
PPC not cross
verifying the
production input vs
PROCESS AUDIT REPORT
FORMAT NO.:KPI/QA/PA/002
production output
AUDITORS
1. Mr.Kumaravel, QMS Lead Auditor.
CORRECTIVE ACTION VERIFICATION AND COMMENTS
VERIFIED:
AUDITOR SIGNATURE
