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GLOBAL SERVICES
CONSULTANCY ON TOTAL QUALITY MANAGEMENT
TRAINING MATERIAL
ON
ISO/TS 16949:2002
INTERNAL AUDITING
GLOBAL SERVICES
SUCCESS THROUGH MANAGEMENT EXCELLANCE
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Chapter
No.
Chapter Name
1.
Cover Page
2.
Table of Content
3.
Introduction
4.
5.
Questionnaire
6.
Definitions
7.
Types of Audit
8.
9.
10.
Auditor Friends
11.
12.
13.
14.
Tips to Auditee
15.
Tips to Auditor
16.
17.
Case Studies
18.
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Chapter 5 Questionnaire :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
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35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
What is the system adopted by your organisation for identifying the date of
implementation of customer change ?
Is it mandatory to have your supplier certified for ISO/TS 16949 Requirements ?
Is it mandatory to review the Delivery performance of your Supplier ?
What are the Purchase commitments to be provided by your organisation to the supplier?
Does the customers representative have the right to visit to your supplier for verification,
as per ISO/TS 16949 standards ? If so, mention the applicable clause ref.
Which of the following is customer supplied product :
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77.
78.
79.
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87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
List out three situations for which production part approval is required unless the
customer part approval activity has specifically waived the requirement.
List out atleast five documents / items to be completed by the supplier for production part
approval.
Differentiate between Corrective Action and Continuous Improvement ?
How would a company show evidence of a Comprehensive Continuous Improvement
Philosophy ?
List out atleast five techniques that can be used for continuous improvements ?
List out atleast five continuous improvement projects being undertaken by your
organisation.
A continuous improvement plan for quality assurance department specifies the following
activity as one of the projects :
Improvement of Cpk value from 0.7 to 1.33 for Process-A, Is it acceptable ?
Is it required to adopt MDT approach for facilities and equipment planning ?
What are the factors to be considered for evaluation of the effectiveness of existing
operations ?
How do you interpret the term Mistake Proofing ?
Explain atleast one mistake proofing methodology used by your organisation during
process planning.
Is it mandatory to carry out full dimensional inspection of the tool ?
Customer Supplied Tooling was identified through a sticker ? Is it acceptable ?
How do you interpret the term Perishable Tool ?
Is it mandatory to have a system, in case tool maintenance activity is out sourced ?
What is the purpose of Advanced Product Quality Planning ?
Which are the Five Phases of APQP ?
How do you define feasibility review ? What is the system for feasibility commitment in
your organisation ?
Which are the requirements to be covered before quality planning sign-off ?
What is the purpose of Design FMEA and what is the purpose of process FMEA ? When
DFMEA is conducted and when PFMEA is conducted ?
How do you define and calculate RPN ? What is Severity, Occurrence and Detection ?
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2.
Auditor : A person who has the qualification and is authorized to perform all or any
portion of a quality system audit.
3.
4.
Major Non-conformance :
5.
Minor Non-conformance :
A failure in some part of the suppliers documented quality system relative to the
Standard.
A single observed lapse in following one item of a company quality system.
6.
7.
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Contact Auditee
Collect Information
Opening Meeting
Auditors Meeting
Conduct Audit
NCR/CAR Meeting
Closing Meeting
Internal Audit
Report
Corrective Action
& Follow Up
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Date
Time
Date : _________
Department
Auditee
Auditor
Scope of
Audit
Management Representative :
Page No. ___ of ___.
Circulation to :
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Who does it ?
Who is doing it ?
Who should be doing it ?
Who else can do it ?
Who else should do it ?
What
1.
2.
3.
4.
5.
What to do ?
What is being done ?
What should be done ?
What else can be done ?
What else should be done ?
Where
1.
2.
3.
4.
5.
Where to do it ?
Where is it done ?
Where should it be done ?
Where else can it be done ?
Where else should it be done ?
When
1.
2.
3.
4.
5.
When to do it ?
When is it done ?
When should it be done ?
What other time can it be done ?
What other time should it be done ?
Why
1.
2.
3.
4.
5.
Why does he do it ?
Why to do it ?
Why to do it there ?
Why to do it then ?
Why to do it that way ?
GLOBAL SERVICES
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How
6.
7.
8.
9.
10.
How to do it ?
How is it done ?
How should it be done ?
Can this method be used in other areas ?
Is there any other way to do it ?
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Responsibility
Activity
Auditor
Non-conformity
Auditee
Disposition Action
Auditee
Root Causes
-
Auditee and MR
Corrective Action
Auditor / MR
Verification of Implementation
and Effectiveness
MR
MR
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SUCCESS THROUGH MANAGEMENT EXCELLANCE
Close Non-conformity
Summary
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Document
Introduction / Change
Awareness / Training to
personnel
Introduction /
Upgradation of
Resources
N o n - c o n fo r m it y
A dequacy
N o t a d d re s s e d
N o t R e fle c t e d
N o t L in k e d
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C o m p lia n c e
N o E v id e n c e
N o t u p d a te d
T w o S ta te m e n ts
N o t F o llo w e d
N o t A v a ila b le
N o t A u t h o r is e d
N o t F ile d
N o t In d e x e d
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Remember, it is not good enough to say that you do a certain thing in the performance of
your job you must be able to prove it with documentation.
Document the rationale of the things you do not do. Document it in procedures and
instructions or exclude it from the scope.
During Audit :
Most Organizations fail external independent audits for one or more of the following reasons :
Identification of material
Documentation control
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Auditor verifies the various sections and its activities in the shop floor.
In servicing department Why these products are lying here ?
Auditee :
These are received from customer for servicing.
Auditor :
Show me any document, which is explaining about verification and control
throughout the process.
Auditee :
Searches ..No it is not defined in any procedure.
Case 5 Department : Production
Auditor :
Verifies the copper pipe bending process being carried out by the operator.
Calls another operator, shows him pipe after the bending process and asks, is it
accepted ?
Operator :
No Not accepted and he explains his views.
Auditor :
Asks same question to third operator.
Operator :
Yes, it is accepted.
Auditor :
Finally Production Supervisor says accepted to the auditor.
Case 6 Department : Production (in shop floor with operator)
Auditor :
Show me document / instruction for this process ?
Auditee :
Shows the process sheet with drawing.
Auditor :
Verifies the revision status of the drawing revision against the Master List of
Drawing held by the Design department.
The master list says revision status 04. Where as the drawing copy received from
operator shows revision no. 02.
Case 7 Department : Production (Process Crimping)
Auditor :
Can you show me document / instruction for this process ?
Auditee :
Shows the work instruction to the auditor.
Auditor :
Tell me how, you will ensure the withstanding pressure ?
Auditee :
Explains the method.
Auditor :
Verifies the work instruction, which is not in line with the statement of the
operator but the auditor feels that method explained by the Operator can also be
applied.
Case 8 Department : Management Representative
Auditor :
Show me the master list of document with the latest revision ?
Auditee :
Shows the master list which indicates the latest revision.
Auditor :
Verifies the Work instruction held by Production against the master list. He
ensures that the revision status is same.
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Found that the appraiser variation (AV), Equipment Variation and (R&R)
are compared against Tolerance in place of total variation.
Case 28 Department QA
Auditor :
March 03
12
Auditee:
Auditor :
Auditee:
Auditor :
Auditee :
Auditor :
Auditee:
April 03
11.95
May 03
11.79
June 03
6
July 03
14
Case 29 : PPAP
Auditor reviewing the PPAP for the part NO. 26544 98 Sr. NO.68146
During the review, auditor finds all the MSA, SPC, INSPECTION REPORT, WARRANT are
available.
Auditor :
Auditee :
Finds for the part no. 27538 (S), No inspection report submission warrant.
It is a subcontracted item
Case 30 : PPAP
Auditor :
Auditee:
During the IQA audit dated on 20.06.98, auditor looks the product
catalogue for the current year. He is asking the PPAP for the part number
for the 96587 9 (0) which is introduced 12th December 97.
PPAP are disposed already because the product is not active.
(Assume the two situations and write answers)
Case 31 :
MRM
Auditor :
Case 32 :
MRM
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Case 33 :
Auditor :
Auditee :
QA
Observes that increasing trend in internal rejection, he asked do you have
any analysis and action plan ?
Shows the analysis details only.
Case 34 : QA
Auditor :
Auditee :
Case 35 : MARKETING
Auditor :
Case 36 : FMEA
Auditor :
Case 37 :
Auditor :
During the review of APQP timing chart and the process FMEA auditor
observes that KEY DATE of FMEA is decided as 14.07.98 & production
date is 07.07.98.
ENGINEERING
Observes that the customer ABC has identified three spl. .characteristics
in their drawing. The supplier XYZ has identified the same
characteristics in the drawings, control plan etc. using suppliers
equivalent symbol.
Case 38 : PRODUCTION
Auditor :
Observes that the reaction plan for drill hole in control plan of drilling
operation is mentioned as Adjust & reset
Case 39 : PRODUCTION
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Observes that the reaction plan is written as Adjust & reset for the
parameter which is controlled through X bar & R Chart.
Case 40 : FMEA
Auditor :
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6.
7.
02.
3.
4.
5.
8.
9.
10.
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Signature :
Date :
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