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Manufacturing process audits

Discussion in 'IATF 16949:2016 - Automotive Quality Systems' started by bkirch, Nov 29, 2018.

  1. bkirch

    bkirch Member

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    In 9.2.2.3(Manufacturing process Audits), one of the requirements is that audits are conducted on all shifts including an appropriate sampling of shift handovers. Could I get some input on what types of things that a manufacturing process auditor might look for during shift handovers?
     
  2. bkirch

    bkirch Member

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    Also in 9.2.2.3(Manufacturing process audits), there is a requirement that states that the audits need to include an audit of the effective implementation of process risk analysis(such as PFMEA), control plan, and associated documents. Could I get some input on they types of things that should be audited that would demonstrate and effective implementation of these items? For example, with PFMEA's, would the audit need to involve auditing the PFMEA's and verifying that they are accurate?
     
  3. Andy Nichols

    Andy Nichols Moderator Staff Member

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    I'd suggest that you can ask yourself simply; "what should happen at a shift hand over?" The model is going to be one of seamless operation. Process equipment should be in place and running to specification. Gauging should be in place and in good condition. Records available. Any non-conforming products made and in reject containers should be recorded (if not yet dispositioned). Part count should be accurate and reconciled. People competent to run the equipment as they were on the previous shift. Availability of control plans, notifications of part changes, alerts put in place during previous shift (if any) and so on. Basically the same conditions should exist on each shift running.

    What the second part of the requirement is seeking is to make sure the operation is per the PFMEA. GM have found that the actual process frequently doesn't align to the PFMEA or the Control plan - so they require "Reverse PFMEA". IATF are asking you to do something very similar and take a look at the PFMEA and observe the line running conditions. Do the various checks, check frequencies and reject modes (failure modes) correlate and so on.
     
    John C. Abnet likes this.
  4. bkirch

    bkirch Member

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    Thank you! That helps a lot.
     
    Andy Nichols likes this.

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