Mace audit Documentation
Sr. No Clause No Resp. Target Date Sign
1 Clause-1 Dheeraj 25/06/2024
2 Clause-2 Dheeraj 25/06/2024
3 Clause-3 Hamid 25/06/2024
4 Clause-4 Himanshu 25/06/2024
5 Clause-5 Rajat 25/06/2024
Sahid Imram/
6 Clause-6 25/06/2024
Himanshu
7 Clause-7 25/06/2024
8 Clause-8 Sahid Imram 25/06/2024
9 Clause-9 Shop Floor 25/06/2024
10 Clause-10 Dheeraj/ Sahid Imran 25/06/2024
11 Clause-11 Spac team 25/06/2024
12 Clause-12 Spac team 25/06/2024
13 Clause-13 Ashok 25/06/2024
14 Clause-14 Spac team 25/06/2024
15 Clause-15 Sahid Imran 25/06/2024
16 Clause-16 --- 25/06/2024
17 Clause-17 Sanjeev, MGMT 25/06/2024
18 Clause-18 Rohit 25/06/2024
19 Clause-19 Rohit, Abhisekh 25/06/2024
Road Map Of Mace audit Documentation
Sr. No Activities Resp. Target Date Sign
Press Shop
Machine Sequence
Identification
Area Defined
Gange Way Clear
Tool Location
Sr. No SHOP FLOOR POINTS Target Date
1. IPP LOCK AND KEY AREA:
- Area to be defined.
- Responsible Person name to be visualized.
1
- Lock and Key Almirah/Box to be identified.
2. MASTER SAMPLES: Customer Approved samples to be kept at a defined location.
1. IPC SEPARATE AREA FOR FG STORAGE (Only at the time of IPC period)
2. SEPARATE TABLE FOR IPC (Only at the time of IPC period)
2 - Authorized person for inspection to be displayed.
- Insp. Standard to be displayed.
1. ABNORMAL SITUATION AT SHOP FLOOR SHEET TO BE DISPLAYED.
2. 4M CHANGE BOARD AT SHOP FLOOR TO BE DISPLAYED AND UPDATED.
3 3. 4M CHANGE WI TO BE DISPLAYED IN LARGE FONT AND LOCAL LANGUAGE.
1. ABNORMAL SITUATION AT SHOP FLOOR SHEET TO BE DISPLAYED.
2. RED BIN AREA:
- Area and Table to be defined.
- CFT team list to be displayed.
8 - Attendance sheet to be displayed.
- lock and key Red Bin to be kept.
- Last month, monthly pareto chart to be displayed
- Red Bin register to be available.
1. STORAGE OF MATERIAL (RM, BOP, WIP & FG) IN COVERED AREA FREE FROM DUST AND
SCRATCHES.
2. Locations for storage of material (RM, BOP, WIP and FG products) to be well defined with FIFO system adherence.
3. Max height up to which RM/BOP material can be stored or stacked.
4. Max quantity which can be kept in a bin/box/trolley to be well defined so that they can be stacked on one another.
5. Min lux level at critical operation and inspection station to be maintained as per IS standard.
6. Working condition of critical operation and inspection stations (noise level, etc.) to be monitored and checked.
Recording should be available.
7. Work table for critical operation (rework, etc) and final inspection & PDI to be defined with responsibilty list added
with skill level of all listed persons.
8. No any leakage (water, oil etc.) to be present at any of the machines in the entire plant.
9 9. No any loose wiring, temporary connections to be present in any machines & equipments.
10. Condition of dies, tools, jigs (no damage, temporary repair etc.) to be perfect.
11. Proper storage of tools/dies in well defined location wise racks and board to trace the location of the dies kept.
12. Condition of inspection equipments (no damage, temporary binding etc.) to be perfect.
13. Storage of inspection equipments safely in its defined case only.
1. Limit Samples of all products to be available + duly filled validation tag in each part to be identified. All limit
samples to be displayed at shop floor.
2. Daily m/c checksheet at each machines to be available with duly fille dup to date.
10 3. OK & NG samples at work stations to be present of only current running part at machine.
4. BREAKDOWN VISUALIZATION AT M/C (Only at time of B/D)
1. Visualizer or alarm at critical operations/machines/workstations for confirmation of completion of work or
abnormalities.
2. Display of Work Instruction and critical process and quality parameters for easy assess ability to operator (should be
11 displayed at direct reading location to operator). In local language so that operator can read and understand it.
1. FIFO System at RM, BOP, WIP, FG area to be implemented well in board and register of inward and issue with back
traceability of each and every part.
2. Identification tags on WIP and FG products for traceability with production lot and date
3. System to avoid mix up of similar parts (use of different colour tags, different colour bins/boxes, different colour
packings) at respective areas.
4. Identification of NG parts by marking on part before keeping in red bin. All operators/workstations to be provided
with marker.
5. Colour of bins to be used for keeping NG parts to be defined (red) and kept at all working stations.
6. System for handling NG parts to be displayed at shop floor.
12 7. Disposal of NG parts (scrap/rework) to be done by QA and shpuld have a record of it.
8. Evidence of analysis of NG parts in red bin.
REOWRK AREA:
9. Procedure/WI for rework of parts to be displayed at rework station.
10. Display of name of the persons authorized to rework and their skill level in the rework station to be displayed
11. Rework record with detail of person who has done rework and approved to be available in a register.
1. Packing standards approved by customer to be available.
2. Display of packing standards at packing area.
BIN CLEANING AREA:
3. Condition of bins/trolleys being used in WIP and FG material to be in good and clean condition.
4. WI for checking & cleaning bins/trolleys to be diplayed at identified bin cleaning area.
5. Display of bin check points at bin cleaning area.
6. List of authorized person with skill level to be defined and displayed at Bin cleaning area.
7. Record of Bin cleaning to be available up to date.
8. Containers used with detergent solution and clean water for bin cleaning to be defined.
13
9. Area for keeping dirty bins and clean bins to be defined.
BIN/TROLLEY REPAIR:
10. WI for repairing of bins/trolleys to be displayed at identified area.
11. Authorized person list to be displayed at the area.
12. Area for keeping damaged and repaired bins to be identified.
13. Record of repairing of Bins/trolleys to be available.
1. List of trained manpower to operate the inspection instruments and test equipments to be displayed at defined
15 location.
1. Top Management daily attendance to be present in attendance record.
17 2. Org. Str. To be displayed in meeting room/ reception area.
1. Fume exhaust system to be available for welding operations (wherever welding operations is present)
2. Escape Route to be diplayed of all floors at company entry gate and individual routes at respective floors.
3. Toilet check sheet display at entry gate of each and every toilets in the company (staff and workers)
4. Rest Area (Tea/snacks) to be defined in the company.
5. PPE Matrix display at each shop floor.
6. Safety Equipments on machines to be installed and in working condition.
7. PPE adherence sheet filled at defined frequency and shall be up to date.
18 8. Accident record to be available.
WASTE AREA:
1. Waste storage area with defined bins in procedure to be available and kept. All bins to be identified with the bin's
19 storage purpose.
2. Authorized person list to be displayed at defined location.
3. Waste record shall be available.
Points For Shop Floor Target Date
1. IPP/IPC LOCK AND KEY AREA:
- Area to be defined.
- Responsible Person name to be visualized.
- Lock and Key Almirah/Box to be identified.
2. MASTER SAMPLES/LIMIT SAMPLE
Every machine And Inspection Area Required Sample
Customer Approved samples to be kept at a defined location.
Shop Floor Displayed Board
1- 4- M change Work Instruction
2- Abnormality Work Instruction
3- 4- M Change Information Board
4- Customer Complaints Board
5- Safety Board
6- Policy (EMS, Code of conduct, POS, Quality Safety Etc.
7- Slogan for Employee Motivation
8- Suggestion Policy
Shop Floor layout
1- Machine Layout As per List
2- Gang way properly Of every machine ( Easy to Movement)
3- Scrap Area, OK Area RM Area Etc.
4- Identification System (Tag etc.)
5- Proper Identification of Machine Shop, Weld Shop, Tool Room,
Inspection Area, Etc.
6- Every Machine Mandatory PPE
7- Lux Level Noise level Recording
Shop Floor Area
1- Incoming Inspection area
2- Rejection Area
3- Rework Area
4- Hold ( Suspected Area)
5- Final Inspection Area
6- Emergency Area
7- Fire Control Area
8- Bin Cleaning Area
9- Wastage Area
10- Employee Lunch Area
11- Escape Route
12- Plant Layout
13- Emergency Exit
