QUALITY AUDITQUALITY AUDIT

NOT A HIDE-’N’-SEEK GAMENOT A HIDE-’N’-SEEK GAME‘‘Fact finding’ practiceFact finding’ practiceTo verify complianceTo verify complianceUnlike inspection which is a ‘fault Unlike inspection which is a ‘fault finding’finding’

Types of AuditTypes of Audit

AdequacyAdequacy Done at intervals of 1-3 yearsDone at intervals of 1-3 years Revisit procedures and processes to check Revisit procedures and processes to check

suitability with environmentsuitability with environment Revisit business processesRevisit business processes Look for improvement in processLook for improvement in process Gaps called “Areas for improvement”Gaps called “Areas for improvement” ComplianceCompliance More frequently- quarter/semesterMore frequently- quarter/semester Documented systems availableDocumented systems available People drawn from outside the systemPeople drawn from outside the system

Product Audit Product Audit May be contractually May be contractually agreed with the customer.agreed with the customer. The customer sometimes employs an The customer sometimes employs an external agency for doing so. If not, done external agency for doing so. If not, done with internal auditorswith internal auditors Planned to be performed at the final stage Planned to be performed at the final stage of inspectionof inspectionFeaturesFeatures: Unannounced, Reinspected: Unannounced, ReinspectedPROCESS AUDITPROCESS AUDIT – done by – done by Inspectors /EngineersInspectors /Engineers

INTERNAL AUDIT:INTERNAL AUDIT:First party auditFirst party audit – By your internal system – By your internal systemSecond party audit Second party audit a) Supplier audit a) Supplier audit b) Customers audit product b) Customers audit product Third party audit Third party audit Consultant/agency- Normally certification is Consultant/agency- Normally certification is accompanied eg: ISO 9000 – valid for 3 years accompanied eg: ISO 9000 – valid for 3 years subject to success of 5 surveillance audits. If there subject to success of 5 surveillance audits. If there is non conformance you are given 3 months time is non conformance you are given 3 months time for corrective action. If there is non conformance in for corrective action. If there is non conformance in process, then it is stated by auditors that it should process, then it is stated by auditors that it should be in place before the next surveillance.be in place before the next surveillance.

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VENDOR/SUPPLIER AUDITVENDOR/SUPPLIER AUDIT

Two stagesTwo stagesi)i) Induction Audit –Induction Audit – Pre- Pre-announcedannouncedii)ii) Performance Monitoring Performance Monitoring AuditAudit – Surprise/ announced – Surprise/ announced

NON-CONFORMITYNON-CONFORMITY

MAJOR – System documented but practice MAJOR – System documented but practice not donenot doneMINOR - Deviation from sytemMINOR - Deviation from sytemeg: 1) Procurement from approved source eg: 1) Procurement from approved source not done - Score is 9 out of 10 not done - Score is 9 out of 10

2) Obsolete 2) Obsolete documents found in the documents found in the work placework place

Minor non conformances are Minor non conformances are realized as a symptom and realized as a symptom and more samples are taken. If more samples are taken. If symptoms do not get repeated, symptoms do not get repeated, then they are dismissed as then they are dismissed as “sporadic” “sporadic” Action warranted if symptoms Action warranted if symptoms repeated repeated

Non Conformance Report (NCR)Non Conformance Report (NCR) given to process owners.given to process owners.

Contains particulars of:Contains particulars of:

- What is the Non conformance- What is the Non conformance- To what does it attribute to- To what does it attribute to- Explain why it is an NC- Explain why it is an NC

““AUDIT IS USUALLY NOT A AUDIT IS USUALLY NOT A SURPRISE EVENT.”SURPRISE EVENT.”

Surprise is inSurprise is in “ “WHAT IS THE WHAT IS THE SAMPLE PICKED UP”.SAMPLE PICKED UP”.

Bhel-Trichy, audit is done in Bhel-Trichy, audit is done in June and December every year.June and December every year.