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Leadership

Special Audit of Key Characteristics in Control Plan

<LEVEL> 5:Very good(More than expectation) 4:Good(Expectation) 3:Average(Less than Expectation) 2:Bad 1:Very bad(Nothing)


Evaluation item Questionnaire 付Point Expectation(4point level)

Final control How many checking points do you Manufacturing operator clearly knows exact number of checking points, which
(or Control at important have? 重
corresponds to the standard, and also less 10 checking poin ts.
1 process) み

Do you have Working instruction### Clear working instruction (inspection instruction) with photo (or picture) put in front of
(Inspection instruction) for this? operator

Is this working instruction All checking points in working instruction (inspection instruction) are cohernt with control
(inspection instruction) coherent plan, and matching with process flow diagram
with control plan ?

Are frequency, responsibe person


### Clearly defined boundary sample, frequency, responsibe person, and the action (scrap or
and action in case of Not OK repaire) in case of Not Ok in working instruction (inspection instruction)
clear?

How do you decide your checking


### Checking points should be up-dated from feedback of final customer (warranty), and
points? customer (PPM), and past internal problems.

Daily check sheets(DCS) Do you have DCS for checking Have DCS for daily doccument of all defects coherent with working instruction (inspection
points records including tally 重
instruction)
2 sheet? み

Do you have graph for dimension


### SPC graph with OK tolerance, process capability with action rule is clearly displayed
check result? somewhere in plant.

Do you have OK first part? ### OK first part is performed every begin ing of shift or every change overs with the evidence
by part and its check sheet

Do you have check sheet for OK


### OK Start of all Poka-yoke and test equipment done with check sheet
Start of Poka-yoke or test
equipment?

Not OK parts control In case of not OK, do you scrap### Operator respect their instruction sheet with boundary sample which is clearly showing
or repair parts? "Scrap or repaire"
3

How do you distinguish scrap and Scrap parts go to red box; repair parts to repair place with identification.
repaire?

In this case, do you feed back to### Immediate feedback to occurrence process, and feedback to GAP leader in case of
occurence process? escalation

In this case, do you stop ### In case of sample check, can clearly identify suspected inventory parts with its traceability
inventory?

How do you repair your parts? ### Working instruction sheet for repair is clearly displayed, including which parts can be
reuse, where they return repaired parts.

Customer feed back Do you have pareto for PPM ### Weekly tracking chart with parato by causes for PPM displayed somewhere in plant
(even from the next process as
4 customer)?

Do you have action plan for Top PDCA exist for Top5 items. Problems completely killed after action.
5?

Incoming parts control Do you have incoming parts They identify incoming parts are OK or NOK.
inspection area in the plant? They can retain parts to be used before inspection is finished.
5

Did you decide checking points Checking points clearly shown in inspection report from supplier
with your suppliers?

Do you have file with periodical Existing file with periodical inspection report from supplier.
inspection report from supplier OK/NOK should be clarified.
for this check result?

Do you periodically audit your Audit plan existing; audit suppliers to improve quality results.
suppliers to prevent quality
concerns?

Total 0

20

Please check that you have the latest version of this document. Page 1/6 FAU-F-PSG-0800/EN
Confidential. Property of Faurecia issue 04
Ref: FIS-F-PS3-0600-en Version: Issue 04
Receiving
Site audited: XXX
Audit Sheet Audit date: 00.00.0000
PRODUCT IDENTIFICATION
Customer: S Proto
Vehicle: Version:
Product name: Workstation No. for this operation: R Series

N° QUESTIONS 0 1 2 3 NA REMARKS

There is an updated list of S/R products avalaible at


1 receiving ( S/R products and characteristics are clearly
defined).

2 There is a certification status list for the S/R products

3 Conformity certificates inlcude S/R characteristics.

Are there any S/R part delivered by a sub-contractor


4 ( supplier who has not developped his own process) ?

There are standard procedures for management of non-


5 conforms.

Criterias of non-conformity ( boundary samples, defect


6 catalog,..) are available

If an intern batch/lot number system is in place, the link


7 beetween internal and external batches is done.

For each supplier delivering S/R Products, Process Audit is


8 either successfull or there is a clear action plan in place.

9 Do you apply control plan for S/R parts ?

A visual monitoring board of supplier performance is


10 available in term of quality and delivery

Receiving is informed about non conforming BOP


11 returned from UAP.

Product Packaging labeling shows S/R Logo ( NA for


12 standard catalogue parts like bolts, nuts, rivets, clips,...)

13 Stock is organized in FIFO ( electronic or FIFO Panel)

Parts/products for trial are clearly identified and stored in


14 a specific place.

0 0 0 0 0 Conformity index
Scoring: NA: A=Not Applicable- B= Not auditing - "0": ignored or respected <10% - "1": respected > 10% - "2": respected > 50% - "3" : respec

409470777.xls (Receiving) (02/16/2019) Page 2 of 6


Ref: FIS-F-PS3-0600-en Version: Issue 04
Product Traceability
Site audited: XXX
Audit Sheet Audit date: 00.00.0000
PRODUCT IDENTIFICATION
Customer: Part reference: S Proto
Vehicle: Version:
Product name: Workstation No. for this operation: R Series
Manufacturer of system: Standard system: YES / NO

N° QUESTIONS 0 1 2 3 NA REMARKS

1 There is an updated traceability flowchart

This flow chart is validated by S/R Division coordinator


2 according to BG procedure

Traceability is ensured for RAW Material ( Plastic, steel,


3 fiber, powder, iso, polyol, skin rolls,…) according BG
Procedure

4 Is the plan in line with customers requirements ?

Traceability is ensured for BOPS ( batches traceability for


5 components including fastenings ) according to BG
procedure

Traceability is ready to accept product changes


6 ( integration of new variante, new component, change of
BOM,…)

In case of system breakdown (minor or major), a backup


7 procedure exists ( paper, hardware replacement, Barcode
Pistol,...)

Reaction rules in case of traceability breakdown are


8 available on the floor. They are signed by
supervisor/Team leaders.

There is a storage procedure for traceability done on


9 paper ( OK for Production, Raw Material certification,…),
Min 15 years.

Computerized operating system

Datas are stored according to standards (for 15 years )


10 with backup

11 The are several people trained for the system

Search test are knowb and has been successfully


12 executed during audit

0 0 0 0 0 Conformity index

409470777.xls (Product Traceability) (02/16/2019) Page 3 of 6


Ref: FIS-F-PS3-0600-en Version: Issue 04
Fastening
Site audited: XXX
Audit Sheet Audit date: 00.00.0000
PRODUCT IDENTIFICATION
Customer: Part reference: S Proto
Vehicle: Version:
Product name: Workstation No. for this operation: R Series
Manufacturer of system: Standard system: YES / NO

N° QUESTIONS 0 1 2 3 NA REMARKS

Are all screw drivers electric? Are they measuring torque


1 and angle?

2 Calibration frequency is defined and respected

Is there a standard procedure for calibrating screw


3 drivers ? ( standard is to use a sensor once a week)

Does it exist a joint test for each class of fastening


4 operation ( one for each class of torque) ?

Is maximum allowed torque inferior to 80% of breaking


5 torque ?

Are tolerances for angle adequate : Guidelines are : 30°-


6 90° for hard fastening and 80°-180° for soft fastening
( plastic part added) ?

Are equipment parameters coherent ? ( edit parameters


7 already set up in the equipment and check out the
various fastening phases)

Is program avoiding to screw a second time the same


8 screw ?

Is screw driver automatically stopped at first non Ok


9 fastening cycle ?

Does the program take into account an unfastening


10 operation? If not, then unfastening must be forbidden at
station.

11 Is rework done with similar equipement ?

How are logged and followed up the reworks within the


12 traceability system?

13 Is there a rework procedure specific for Torque control?

Product SR characteristics and process SR parameters


14 defined in drawings, DFMEA and PFMEA are clearly
defined in the control plan

Conformity of product is defined in the control plan


15 (method, mean used, frequency…)

Is the short term capability of the product characteristics


16 good ( > 2 ) from SOP and Gage R&R accepted ( < 10%)

Process parameters affecting SRC are either :


- under process control at each cycle ( Machine
17 parameters) or
- monitored through SPC chart

There has been trials to define nominal and tolerance


18 values for all parameters

409470777.xls (Fastening) (02/16/2019) Page 4 of 6


Ref: FIS-F-PS3-0600-en Version: Issue 04
Fastening
Site audited: XXX
Audit Sheet Audit date: 00.00.0000
PRODUCT IDENTIFICATION
Customer: Part reference: S Proto
Vehicle: Version:
Product name: Workstation No. for this operation: R Series
Manufacturer of system: Standard system: YES / NO

N° QUESTIONS 0 1 2 3 NA REMARKS

Is the Quality Dept formally included in validation of


19 parameters ?

20 Access to critical settings is protected? (Key or password)

If action is executed incorrectly, part cannot be passed


on to next workstation or to the end of the production
line :
21 - either there is an automatic shutdown preventing
operator recovering part without reset key or pasword
- or there is an automatic dest

Do you apply a procedure for production start up that


22 checks and records the process, controls and Poka-Yoke. (
QSE Basics)

Are changeovers, for different models, under control with


23 Poka Yoke ?

Wrong loading positioning of part(s) on fixture/tool


24 prevents system from starting

Are the SR operating instructions posted, updated and


22 known by the operator?

S/R marking at the workstation is adapted conformed to


23 Faurecia standards. (S/R logo with SRC identification at
the workstation).

The operator has received formal S/R training?


24 (registered and support available)

25 Non-conforms are managed following QSE rules

Results 0 0 0 0 0 Conformity index


Scoring: NA: A=Not Applicable- B= Not auditing - "0": ignored or respected <10% - "1": respected > 10% - "2": respected > 50% - "3" : respec

409470777.xls (Fastening) (02/16/2019) Page 5 of 6


Ref: FIS-F-PS3-0600-en Version: Issue 04
Other Process 1
Site audited: XXX
Audit Sheet Audit date: 00.00.0000
PRODUCT IDENTIFICATION
Customer: Part reference: S Proto
Vehicle: Version:
Product name: Workstation No. for this operation: R Series
Manufacturer of system: Standard system: YES / NO

N° QUESTIONS 0 1 2 3 NA REMARKS

Product SR characteristics and process SR parameters


1 defined in drawings, DFMEA and PFMEA are clearly
defined in the control plan

Conformity of product is defined in the control plan


2 (method, mean used, frequency…)

Is the short term capability of the product characteristics


3 good ( > 2 ) from SOP and Gage R&R accepted ( < 10%)

Process parameters affecting SRC are either :


- under process control at each cycle ( Machine
4 parameters) or
- monitored through SPC chart

There has been trials to define nominal and tolerance


5 values for all parameters

Is the Quality Dept formally included in validation of


6 parameters ?

7 Access to critical settings is protected? (Key or password)

If action is executed incorrectly, part cannot be passed


on to next workstation or to the end of the production
line:
- either an automatic shutdown prventing operator
8 recovering part without reset key or pasword
- either an automatic destruction of the NC part at station
- either throgh a physical identification
- either an automatic part segragation through bar code
Do you apply a procedure for production start up that
9 checks and records the process, controls and Poka-Yoke. (
QSE Basics)

Are changeovers, for different models, under control with


10 Poka Yoke ?

Wrong loading positioning of part(s) on fixture/tool


11 prevents system from starting

Are the SR operating instructions posted, updated and


12 known by the operator?

S/R marking at the workstation is adapted conformed to


13 Faurecia standards. (S/R logo with SRC identification at
the workstation).

The operator has received formal S/R training?


14 (registered and support available)

Non-conforms are managed following QSE rules Group


15 (Rework under Control and non conformities
management)

Results 0 0 0 0 0 Conformity index

409470777.xls (Other Process 1) (02/16/2019) Page 6 of 6