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Stock Audit Check List document sample
Document Sample
f9954ade-b6f1-4a8f-aa85-89d8e288820f.xls Checklist Printed 8/18/2011
A. Metrics AUDIT WORKSHEET
QUESTION: EVIDENCE G/Y
LOOK FOR Score OBSERVATIONS
In regard to the Metrics, REQUIRED /R
Posted record
Is Downtime Analysis by department, Chart updated w/in
1 on the shop R
Production Plan vs. Actual, posted? 30 days
floor
Posted record
Is Scrap Analysis by department, Chart updated w/in
2 on the shop R
Production Plan vs. Actual, posted? 30 days
floor
Is the Voice of the Customer posted? Posted record
Chart updated w/in
3 (Charts for PPM, # of PRR's and Major on the shop R
30 days
Disruptions) floor
Posted record
Is Rework Analysis by department, Chart updated w/in
4 on the shop R
Production Plan vs. Actual, posted? 30 days
floor
B. Standardized Work at each operation AUDIT WORKSHEET
QUESTION: EVIDENCE G/Y
LOOK FOR Score OBSERVATIONS
In regard to Standardized Work, REQUIRED /R
Elements of Each operation to
At each operation, that has a human
work are have elements
1 working, are the elements of work within a R
identified with posted with order
cycle with times posted?
time and time.
Each operation to
Is the total cycle time identified at each Cycle time at
2 have the cycle time R
operation? each operation
posted.
Diagram Each operation to
showing each have a diagram
Is each operation diagramed showing the
3 element, order showing the work R
operator's path and work order?
of element and order of each
operator's path element posted.
Audit sheets Daily standardized
Is each operation audited to see that
4 with sign-offs of work audits posted R
standardized work is followed?
each review at each operation
Posting of part
Correct part
numbers used
5 Is the Bill of Material posted at each job? numbers being used R
at each
at each operation
operation
A listing of all Each operation to
Is there a graphic showing the required required tools have a graphic with
6 production tools and safety equipment and safety tool and safety R
needed at each operation? requirements at equipment
each operation requirements
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f9954ade-b6f1-4a8f-aa85-89d8e288820f.xls Checklist Printed 8/18/2011
An insignia (ie
KPC are
diamond) that
Are Key Product Characteristics identified highlighted at
identifies any KPC
7 at the station(s) that produce(s) that each operation R
at an operation that
characteristic? that effects the
produces the
KPC
characteristic
Posting within
each
department
Is operator certification posted for each Training Matrix
8 with operator R
operation? posted
names that are
certified for
each operation
Problem
5 Phase or other
solving
problem tracking
Are problems documentation worksheets worksheet for
worksheet posted at
for any customer dissatisfies (PRR) PRR's caused
9 operations where R
posted at the operation where the error by that
errors were made
was made within the last 12 weeks? operation within
and PRR
the last 12
documented
weeks
Agreed upon
completed Sample board with
Are boundary samples present for each
10 component signed-off R
part produced?
boundary boundaries
samples
Job element
within standard
Inspection element
identifying
Are successive checks identified in work documented to
11 inspection of R
elements? review prior
previous
operation
operation's
work
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f9954ade-b6f1-4a8f-aa85-89d8e288820f.xls Checklist Printed 8/18/2011
C. Material AUDIT WORKSHEET
QUESTION: EVIDENCE G/Y
LOOK FOR Score OBSERVATIONS
In regard to Materials, REQUIRED /R
Label with part Part numbers
Are parts storage areas at each operation
numbers at identification at each
1 labeled to show part numbers stored at R
each storage operation where
that location?
location parts are stored.
Part container
Look for stock dates
dates at each
Is First In/First Out maintained at each at each storage
2 operation show R
operation? location for each
oldest material
operation
being used first
Min/Max
Overstocking or
inventory label
understocking of
Are Min/Max quantities displayed at each at each
3 material based upon R
operation's part storage location? operation's
min/max
storage
requirements
location
Build-up of
Operator is not
4 Is the operator working ahead? subassemblies or R
over producing
excess WIP
Operations are
Material is not
Is Work In Process minimized? (If balanced and one
be stored
5 operations are not bottlenecks, is one operation is not R
between
piece flow being utilized) overproducing
operations
versus another.
D. Quality System (Method) AUDIT WORKSHEET
QUESTION: EVIDENCE G/Y
LOOK FOR Score OBSERVATIONS
In regard to the Quality System, REQUIRED /R
Signals to operators
Error detection
1 Is there any error proofing present? that an error has R
is present
been made.
A test rabbit is
Documented
Are procedures are clear to check and utilized to verify
2 daily audit of R
verify functioning of error-proofing? function of error-
error proofing
proofing
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f9954ade-b6f1-4a8f-aa85-89d8e288820f.xls Checklist Printed 8/18/2011
Part measured
Dimensional
3 Verify a part is within specification with production R
discrepancies
gages
Operator
Control Plan instructions and
4 Is the control plan being followed and Operator reaction plan per R
Instructions current control plan
located in dept.
Process control and
Are KPC's statistically tracked at the
5 Control Chart capability R
operation(s) that produce them?
improvement
Calibration
Are Product Measurement Systems Sticker on the Gage tag and how
6 calibrated and work instructions to utilize gage < 1 yr old the operator follows R
the gage present? and work gaging instructions
instructions
E. Environment AUDIT WORKSHEET
QUESTION: EVIDENCE G/Y
LOOK FOR Score OBSERVATIONS
In regard to Environment, REQUIRED /R
Areas to be sized to
Space with accommodate all
1 Are Meeting areas provided? R
chairs members within a
team.
Performance charts,
Department
Organizational wins,
Is key information provided by performance to
2 Organization vision, R
management to the shop floor? business to
priorities and
plan is posted
objectives
Posted team
Meeting
performance and
3 Are team meetings conducted monthly? minutes/team R
actions based upon
reporting
meetings
F. Process Failure Modes and Effects Analysis (PFMEA) AUDIT WORKSHEET
QUESTION: EVIDENCE G/Y
LOOK FOR Score
In regard to the PFMEA, REQUIRED /R
OBSERVATIONS
Are cross functional team members Team members
1 Training records
trained in developing PFEMA? on PFMEA
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f9954ade-b6f1-4a8f-aa85-89d8e288820f.xls Checklist Printed 8/18/2011
Recent revision
Is it a living document; does it cover items Updated due to
date, change
of past concerns based on recent PRR's a recent PRR,
history, new items or
2 and current line rejects, when the same line rejects, or
changes in RPN
concern affects several similar parts or similar part /
numbers, similar
processes, are they all updated? process
parts or processes
Look for
standarize
ranking per
AIAG standard,
Are all steps in the process flow included
which covers Correlation between
in the PFMEA? If an item has high a
3 the entire PFD and PCP and
severity rankings or high RPN's, does it
process PFMEA
have a KPC's or KCC's relate to it?
receiving to
shipping
including
rework.
Documented Corrections to: Top
What is suppliers continuous
Process XX or %, RPN > XX,
improvement process for reducing RPN's
reviewed by High # in any
(gap analysis to ideal)? Are Risk Priority
4 management category, with
Numbers (RPN) recalculated after
with examples examples of
recommended corrective actions were
of completed completed action
completed?
action items items
Suppliers with
rejects in last
Completed copies of
Tiered Supplier’s PFEMA SFE check list 12 months
5 suppliers SFE for
availability ? need SFE
PFMEA section
PFMEA section
completed
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f9954ade-b6f1-4a8f-aa85-89d8e288820f.xls Checklist Printed 8/18/2011
G. Quality in Station AUDIT WORKSHEET
QUESTION:
EVIDENCE G/Y
In regard to Building Quality in LOOK FOR Score OBSERVATIONS
REQUIRED /R
Station
Operators
signal for help
Are there visual or audio signals
and support Operators calling for
1 identifying problems found by the R
can receive assistance.
operator(s)?
signal
immediately
Communication
signal for
Is Andon clear to everybody, e.g. location Light Boards, lamps,
2 maintenance or R
and nature of problem? or audio signals
operator
support
Andon's function
Function
3 Does Andon function without trouble? and response to R
Andon
request
Continuous
Documentation
improvement data
Is Andon tracked and problem solving in with tracking of
4 for line R
place to reduce the number of calls? improvement
stoppage/downtime
plans
from Andon
H. 5-S (Workplace Organization) AUDIT WORKSHEET
QUESTION:
EVIDENCE G/Y
In regard to the Workplace LOOK FOR Score OBSERVATIONS
REQUIRED /R
Organization,
No excess
equipment/tool Things not being
Are only things that are part of the
1 s or parts used to produce in R
process existing in the work area (Sort)?
present in work the work area
area
Floor markings Materials in the work
and signs area without
Are things set in order with visual controls
2 identifying designation of what R
present(Set in Order)?
everything in it is or where it
the work area belongs.
Only debris
from the past
24 hours of Leaking equipment,
3 Is the area clean(Shine)? production debris being R
appears collected over time
present in the
work area
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Required cleaning
Housekeeping
materials and their
tasks are
Housekeeping is identified in work locations are
4 defined in the R
standards (standardized)? identified within the
work
workplace
instructions
organization
Audit checklists Shop floor
Does management audit housekeeping
5 and records of documentation and R
and workplace organization(Sustain)?
audits results
I. Management AUDIT WORKSHEET
QUESTION: EVIDENCE G/Y
LOOK FOR Score OBSERVATIONS
In regard to Management, REQUIRED /R
Improvement
Does Management send messages of goals and postings in a
1 continuous improvement on the shop objectives location that is R
floor? posted in visible/accessible.
department
Problem
communication
matrix indicating
Management
Is management frequently on the shop which
2 presence in R
floor? circumstances
work area
certain levels of
management
requires notification.
Audit review
area, review Daily meetings
Are there daily performance reviews with data and covering data from
3 R
goals clearly communicated? objectives the customer and
present on the internal audits.
shop floor
Latest line item for
the Automotive
Has the latest QS/TS Certificate been Creativity Team
certification status in
4 sent to the appropriate GM QS/TS Bid list shows R
QS module of GQTS
Coordinator? green for QS.
shows "Certified" for
this Duns.
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J. Rework/Sort AUDIT WORKSHEET
QUESTION:
EVIDENCE G/Y
In the rework and sorting of LOOK FOR Score OBSERVATIONS
REQUIRED /R
product,
Part labels
Repair materials not
identifying
Are rework materials marked and stored clearly identified or
1 rework and R
in clearly defined areas? located in
defined storage
undesignated areas
of rework
Approved
Are rules and procedures clear when A list of reworks and
2 rework R
rework is needed? procedures for each
procedures
Material flow of
rework back
Inventories of
3 Are rework materials reverified? through normal R
reworks
production
audits
Containment driven
Are countermeasures to problems Countermeasur
4 back to the source R
managed effectively? e log for rework
of error.
K. Machine/Tooling AUDIT WORKSHEET
QUESTION:
EVIDENCE G/Y
In regard to the machinery and LOOK FOR Score OBSERVATIONS
REQUIRED /R
tooling,
Maintenance A log of
Do maintenance checklist exists for
1 checklist at maintenance activity R
machinery and tooling?
operation at the equipment.
At machinery,
Do maintenance trouble log exists and are Time down on
2 an up to date R
they posted at the machinery? maintenance log.
trouble log
During review
No disruptions
3 Are machines running without trouble? are machines R
during review
running.
Control Chart
Are machine control characteristics or out of control Uncontrolled
4 R
tracked/controlled at each machine? signal (Audible equipment
or Visual)
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f9954ade-b6f1-4a8f-aa85-89d8e288820f.xls Summary Printed 8/18/2011
Supplier: Duns Code: Date:
Location: SQE/Team Auditors:
Part Desc. Plant Mgr.
General Motors Shop Floor Excellence Review
Metrics: Information Displayed(Method) Quality in Station(Method)
0 Downtime 0 Voice of the Customer 0 Visual or audio signal identifying problem found by operator
0 Scrap 0 Rework 0 Andon is clear to everybody, e.g. location and nature of problem
0 Total Potential 16 0% 0 Andon functions without trouble
Standardized Work at each operation(Method) 0 Andon is tracked and problem solving is in place
0 Each element of work identified with time 0 Total Potential 16 0%
0 Total cycle for each operation identified Workplace organization: 5S(Method)
0 Diagram showing elements and order 0 Only things that are part of the process exist in work area(Sort)
0 Signed off standardized work audit sheets 0 Things are set in order with visual controls present(Set in Order)
0 Bill of Material 0 The area is clean(Shine)
0 Required production & safety equipment graphic 0 Housekeeping is identified in work standards(Standardize)
0 Key Product Characteristics identified 0 Management audits housekeeping and workplace organization(Sustain)
0 Operator Certification posted/documented 0 Total Potential 20 0%
0 Problem documentation worksheet e.g. 5 phase, 8D Management(Method)
0 Boundary Samples are present 0 Sends messages of continuous improvement
0 Each operation verifies previous operation's work 0 Are frequently on the shop floor
0 Total Potential 44 0% 0 Daily performance reviews with goal clearly communicated
Material(Material) 0 Latest QS/TS Certificate sent to GM Coordinator
0 Parts storage area of inventory identified, e.g. shelves labeled 0 Total Potential 12 0%
0 First In/First Out is maintained at operation Rework / Sort(Method)
0 Min/Max quantities are displayed at storage locations 0 Rework materials are marked and stored in a clearly defined area
0 Operator is not working ahead 0 Rules and procedures are clear when rework is needed
0 Work in process is minimized (one-piece flow) 0 Rework material is reverified
0 Total Potential 20 0% 0 Countermeasures to problems are done effectively
Quality System (Method) 0 Total Potential 16 0%
0 Display of error proofing exists Machine/Tooling(Machine)
0 Procedures are clear to check and use error proofing 0 Maintenance checklist exists machinery and tooling
0 A part is verified within specifications 0 Machine trouble log exists and is posted at the machine
0 Control Plan is being followed 0 Machines running without trouble
0 Key Product Characterisitic data is on the floor 0 Machine Control characteristics are tracked at operation
0 Measurement systems are calibrated with operator instrutions 0 Total Potential 16 0%
0 Total Potential 24 0% % Pts Summary Status
Environment(Environment) 0% 0 Displayed Metrics RED
0 Meeting areas are provided 0% 0 Standardized Work at each operation RED
0 Key information is shared by management e.g. Business performance and wins %
0 0 Material RED
0 Team Meetings are conducted at least monthly 0% 0 Quality System RED
0 Total Potential 12 0% 0% 0 Environment RED
PFMEA 0% 0 Quality in Station(Method) RED
0 Are cross functional teams trained 0% 0 Workplace Organization RED
0 PFMEA updated with all nonconformity data (living document) 0% 0 Management RED
0 RPNs match Process Flow Diagram and include KPC/KCCs 0% 0 Rework / Sort RED
0 RPN reduction process developed, and followed by mgt. 0% 0 Machine RED
0 Tiered Supplier’s PFMEA SFE check list available 0% 0 PFMEA RED
0 Total Potential 20 0% 0% 0 Overall RED
Summary Scoring:
Pts Element Scoring Green 80%
0 Element is not in place and no evidence of plans to implement Yellow 60-79%
1 Element is not in place but a plan to implement is documented Red <59%
2 Element is in place but it is not being followed
3 Element in place but not followed at each job or all the time
Rev 7 4/11/01
4 Element is in place and it is being followed
