AUDIT DATE :

PROCESS AUDIT REPORT

FORMAT NO.:KPI/QA/PA/002

AUDIT DATE :28.08.15AUDIT NUMBER:PAR - 002

DEPARTMENT:PRODUCTION

PROCESS: ALL PROCESSAUDITOR:KUMARAVEL

PREVIOUS AUDIT DATE:NAAUDITEE(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 monitor the rod bundle status, it is also good system, but not included in process.

Dill raj

30.09.15

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 produced is arrived, but not verified and no such process

Dill raj

30.09.15

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, 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).

Dill raj

30.09.15

Overall man things followed, but not documented and displayed as procedures.

Sawing and Chamfering:Observations

Responsible Person

Target Date

Status

Before chamfering area, bins area placed for temporary storage, not identified only paint markings available.

Mani

19.09.15

Measuring instruments used in chamfering area found without calibration sticker and operator doesnt aware about the calibration of instruments.

Kumar

19.09.15

For a single rod how much parts can be produced and quantity management is not listed and operator unaware about this process.

Mani

19.09.15

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.

Mani

19.09.15

Skill matrix need to be updated. Old one available.

Mani

19.09.15

Chamfer jig list with manually corrected specs available and also stick on the chamfering machine. Prepared and approved sign not available.

Muthu

19.09.15

Heat number location availability in the rods, unaware to the operator.

Mani

19.09.15

Colour bin identification unaware to the operators.

Mani

19.09.15

Operation manual numbers were not matching with QC process check sheets.

Muthu

19.09.15

Bonde:Observations

Responsible Person

Target Date

Status

Operator having 7 months experience and handling machines individually cannot be a under training person. Skill matrix need to be revised.

Mani

30.09.15

Lot management hanging board system followed for traceability, which was not included in the QC process check sheet or any other document.

Muthu

30.09.15

Operating manual mentioned as KPI/PROD/WI/005 in QC process check sheet not available in bonde area.

Muthu

30.09.15

In sulphuric acid bond rising point management sheet point mentioned as 10-19, but as per QC process check sheet it is 9.5-19, need to be changed.

Muthu

19.09.15

In that operating manual available for points checking level of measurement and burette used for that purpose not included.

Muthu

30.09.15

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.

Muthu

30.09.15

Bonde operation standard KPI/PRD/F/11 displayed not mentioned in QC process check sheet.

Muthu

30.09.15

Operating manual prepared for degreasing water bread chemical mixing is not included in QC process check sheet.

Muthu

30.09.15

Press:Observations

Responsible Person

Target Date

Status

Operators who are well trained should not be at the level of work under supervision. Need to be changed.

Mani

30.09.15

Operator Moganaranga left the job still available in the Skill matrix, to be removed.

Mani 30.09.15

20 numbers once cleaning not documented. which is also not documented.

Muthu

30.09.15

Hydraulic press die list available without documents number, prepared, approved sign.

Muthu

30.09.15

Setting conditions available in the operation standard unavailable to the operator, but they are simply putting ok in QC process check sheet.

Mani

30.09.15

Sawing and chamfering machine Operator who will also run the press machine, skill matrix not updated.

Mani

30.09.15

Weight and Visual inspection:Observations

Responsible Person

Target Date

Status

F/M/L check by QA inspector not included in the QC process check sheet.

kumar 30.09.15

Inspection manual for weight and visual inspection not available Kumar 30.09.15

Weighing machine used in chamfering machine not calibrated. kumar 30.09.15

After introducing new weighing machine, validation not done and records not available. Kumar 30.09.15

Weight machine calibration display not available

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 lot quantity not matching.

Gopal 30.09.15

Defect samples display in the shop floor is not properly available and visible.

Kumar 30.09.15Dispatch:Observations

Responsible Person

Target Date

Status

FIFO not followed properly while moving Forged parts to FG.

Dilli 30.09.15

Dispatch procedure not available and displayed, also to be included in the QC process check sheet.

Dilli 30.09.15

Packing checklist to be followed.

Dilli 30.09.15

Packing standard not available, not displayed and PPC person unaware about that.

Dilli 30.09.15

PPC not cross verifying the production input vs production output

Dilli 30.09.15

AUDITORS 1. Mr.Kumaravel, QMS Lead Auditor.CORRECTIVE ACTION VERIFICATION AND COMMENTSVERIFIED:

Auditor Signature