Stock Audit Check List - Excel

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					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


                                                                                   1 of 9                                Rev7 4/11/01
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




                                                                                2 of 9           Rev7 4/11/01
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



                                                                                       4 of 9                               Rev7 4/11/01
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




                                                                                   5 of 9        Rev7 4/11/01
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

                                                                                    6 of 9                                 Rev7 4/11/01
f9954ade-b6f1-4a8f-aa85-89d8e288820f.xls                                         Checklist                            Printed 8/18/2011



                                                                  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.




                                                                                   7 of 9                                Rev7 4/11/01
f9954ade-b6f1-4a8f-aa85-89d8e288820f.xls                                        Checklist                            Printed 8/18/2011



    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)




                                                                                    8 of 9                              Rev7 4/11/01
     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

				
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Description: Stock Audit Check List document sample