taehwa 6 tool motor audit-ii

C&M Go

08.11.10

CONTENTS

3

2

Process audit overall 1

Q-System audit result

5

Process audit list : 6 Tool

Process audit list : Condition control

Process audit list : T5S

Auditor : Atul Arora

4 Process Audit List :

Outgoing assurance /CTQ Control

6 NC point of Process Audit

1 / 7

Vendor) Q-System audit result approval

In charge approval

C&M Biz. Team

Vendor Taehwa Ent. India Pvt. Ltd. Motor Line

Audit dt. 02nd Nov,2010 Obtained mark

Grade

Auditor Atul Arora Attended by from Taehwa

Mr. M.K Singh, Mr. Ravi 99 A, B, C, D

category Item Allotted mark

Obtained mark

6-tools

Quality meeting

9

5.1OS&D control 8 5.8

Sequential inspection

8

6.3Key process

control8

5.9T/Check 9 6.8Q-audit 8 4.0Total 50 33.9

4 M control

Man 5 3.5Machine /tools 5 3.0

Materials 5 3.3Method 10 6.4

Information of 4 M changes

5

3.3Total 30 19.5

Outgoing quality assurance /CTQ control

20 11.6

T5S 50 34

Opinion about overall audit

result

[Good points)

Time Check

Customer Critical Process Control

Incoming inspection started

[Major problems]Review Mgmt poor - No weekly Q review - No Monthly Q-Review Supplier control Weak Process Control not OK LG Return Rej Analysis Gauge R&R Plan not available Machine Maint./ Tooling mgmt not OK.

Previous Audit history

Audit dt. Mark Grade Audit dt.

Mark Grade

27th July ‘10

55 D

•Grade (Grade A : 150~131 points, Grade B : 130~111 marks,

Grade C : 110~91 mark, Grade D : lower than 90) • F/up of result (Higher than Grade B : Pass, to publish NCR report,

Lower than Grade C : re-audit and to link to biz wrap up???)

Audit check list – 6 tools

2 / 7Profitable Market Share Growth

Item Detailed audit item

Excellent -- Bad calculation

Obtained mark Opinion from auditor

5 4 3 2 1

1) Quality meeting (9 points)

1) Is daily quality meeting being held?

5.1

. 1)Weekly and monthly quality meeting not being held. 2) Action Plan not available for weekly Quality Meeting

2) Is daily quality meeting record being maintained properly?

3) Is Quality index being recorded in the quality status board? - Part RTN defect rate (monthly), process defect rate (daily, monthly)

4) Is weekly quality improvement meeting being held?

5) Is monthly review meeting being done?

6) Is F/Up for the decided item being done

2) OS&D control (8 points)

- Return set control

1) Is RTN, IQC reject, and claim received set being recovered immediately?

5.8

1) Second vendor follow-up not available

2) Improvement action plan for supplier improvement not available

2) Is NG set being displayed for a specified period?

3) Is defect phenomena being taught to operator? (Is operator aware about NG?)

4) Is countermeasure for the NC item being replied in time?

5) Is the detail regarding 2nd vendor being F/B and is its countermeasure being followed?

3) Sequential inspection

1) Is self/sequential inspection item being set and followed?

6.3

1) Overall, sequential inspection activity is lacking. 2) Operator wise self & sequential record not maintained2) Is NG set being recognized by putting tag or

marking with marker?

3) Is NG set being kept in defect box?

4) Is operator wise record being maintained?

5) Is countermeasure for the defect been set?

6) Is prize being awarded as per the achievement of each operator?

∑xin

×1.8

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Audit C/List – 6 Tools


Item Detailed audit item Excellent -- Bad calculatio

nObtained

mark Opinion from auditor 5 4 3 2 1

4) Key process control (8 points)

1) Has key process sign board been attached on the problem process?

5.9

1) History control with improvement plan

2) Is check sheet being made and is supervisor checking the performance?

3) Is key process control liked with history control and improvement activity?

5) T/Check

1) Is T/Check being carried out time wise (initial, mid, final)?

6.8

1) NG Item Action Plan not available

2) Has surface plate, measuring equipment, jig, and check sheet etc. been displayed?

3) Is actual set being kept as first set, mid production set, and final set wise?

4) Is line leader, production head checking whether T/Check is being done?

5) Is NG immediately corrected and its improvement activity being carried out?

3) Q-Audit System

1) Is Q-audit system been assigned?

4.0

3) Q-system Audit Action Plan not availableAudit grade comparison not available

2) Is A-audit being carried out on a monthly basis?

3) Is checking being carried out as per Check standard?

4) Is Q-Audit evaluation sheet being made?

5) Is improvement activity being carried out for the NC item?

6) Is audit result (mark, NC point) being displayed and shared?

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∑xi

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Audit C/List - 4 M condition control


Item Detailed audit itemExcellent --

Badcalculation Obtain

ed mark

Opinion from auditor

5 4 3 2 1

1) Man (5 marks)

1) Is QC organization made and being operated (see organization chart) ?

3.5

1) No training plan for executive level

2) Is training plan been set and is training given to all the employee?

3) Is operator aware about CTQ, T/Check, sequential inspection for his process? (more than 3 operators)

4) Is OJT, necessary training given to operator if operator in process changed?

2) Equipment /tools (5 marks)

1) Is history card for production equipment, tools available and newly making, repair, modification, and shifting history being recorded?

3.0

1) Overall Equipment control lacking 2) Preventive maintenance check

point & check sheet to be implemented

2) Is operation std. been set and displayed in major production equipment and is checking being done as per checking std.?

3) Is equipment running condition been complied and isn’t worker change the condition arbitrarily? (C-gun, to assign in charge, and to mark of no arbitral change)

4) Is tool control condition after production OK? (To check whether tool condition is being checked, cleaning, and keeping method)

3) Materials (5 marks)

1) Is raw materials report (std.) available?

3.32) Is incoming low wise materials report (mill sheet) been obtained and controlled?

3) Is materials incoming and outgoing log book being controlled?

4) Is tracing system available in case there is problem in raw materials?

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5 / 7

Audit C/List - 4 M control

Profitable Market Share Growth


Bad CalculationObtain

ed mark


5 4 3 2 1

4) Method (10 marks)

1) Is QC, 4M control chart been made?

6.4

1) Motor runout check point put in drg but not added in Patrol inspection check sheet2) There is no audit report for the 2nd vendor.

2) Is working standard been displayed in the process? (more than 80%)

3) Is working std. and work matching and is working condition being complied (to check key process)

4) Is changed contents of working method and inspection method been revised and controlled (process chart, standard) in chase working method and inspection method are changed?

5) Is drawing from customer been entered in drawing log book and is its history being controlled and is its latest version being marked?

6)Is specification log book being recorded and is its contents being arranged in drawing and is it being feed/back to related dept?

7) Is process audit and vendor audit report for 2nd vendor been prepared and is periodical audit being carried out?

8) Is incoming quality inspection and history control for the 2nd vendor being carried out?

9) Is necessary measuring instrument available and calibration being carried out periodically? (Measuring equipment history card)

3) Materials (5 marks)

1) Is raw materials report (std.) available?

3.32) Is incoming low wise materials report (mill sheet) been obtained and controlled?

3) Is materials incoming and outgoing log book being controlled?

4) Is tracing system available in case there is problem in raw materials?

∑xi

n×2.0

∑xi

n×1

Audit C/List – Outgoing quality assurance/CTQ control



Bad CalculationObtain

ed mark


5 4 3 2 1

Outgoing quality assurance (20 marks)

1) Is separate OQC inspector been assigned in QC organization chart and is it being operated?

11.6

1 ) Gauge R&R Plan not available2) CTP Item not selected3) For critical processes like Crimping ht CTQ value not monitored , neither Z value trend made available.

2) Is item wise OQC inspection item been assigned and is inspection history card available?

3) Is OQC inspection history being controlled per every lot? (Control with inspection report & system)

4) Is OQC inspector controlling the quality problem and spec. changes history?

5) Is Lot tracing possible by classifying outgoing lot wise production date?

6) Is identification card attaching for the inspection ready /inspection completion/ NG item been classified?

7) Is measurement and item wise possible measuring instrument been equipped as per outgoing inspection item?

8) Is periodical gage R&R being carried out with customer for the outgoing item?

9) Is important quality been selected as CTQ item and is CTQ item adjustment history been controlled on a monthly basis?

10) Is CTP control item been selected for the satisfaction of customer?

11) Is improvement activity being carried out during process capa. analysis and when target value (Z) is not achieved?

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n×4

진단 C/List – T5S


Audit item Grade E Grade D Grade C Grade B Grade A Obtained mark

Opinion from Auditor

5S Arrangement and organization 10

Unnecessary item, NG item, left over from production are left at site without marking 2

Unnecessary item being handled without any plan Part mixed stacked. 4

Temporary disposal place assigned, periodically disposed Depot area control 6

Whenever unnecessary item is found, it is disposed as per rule Standard inventory /stock quantity is being complied 8

Basic system to prevent defect recurrence is available Linked to decreases in inventory/ stock 10

8 points

Cleaning and cleanness 10

Floor, wall not cleaned and dirty. 2

Cleaning tools control, drinking water control, dressing place control OKFloor, wall, and ceiling is clean 4

Cleaning area, in charge frequency clear. Corner, drinking water, dressing area 6

Equipment cleaning is being done periodically Equipment in charge posted and operated 8

Habituated cleaning and maintaining cleanness Basic improvement activity is being done to prevent contamination

6 points

Machine owner not decide for 5S

3R Right location, right quantity, Right container 10

Inventory stacked on gangway, floor. Part, tools left on the floor 2

Having concept of gangway and having simple concept of right location level. 4

Controlling the system by which location, item, and amount can be figured out. 6

Right container, right quantity is being complied and kept at right location 8

The system by which 3 R is being complied. Bin /pallet /container 10

6 points

Location not defined for rework material

Visible management

Finding out abnormality, handling the abnormality 10

The system by which normal and abnormal can not be figured out. 2

The system by which operator can not report by self when any problem is occurred. The condition in which only related personal handles. 4

The system by which operator can report by self when any problem is occurred. Controlling done by linking to related dept. 6

The system in which anyone can find out problem and solve Abnormal condition is controlled cumulative way and linked to improvement 8

Problem condition is being controlled in the form of data, systemization

10 8 points

Status board control 10

The system by which production status, loss can not be figured out. 2

Production status, loss status not being controlled Status board control lacking 1

Production target vs. result control Cleanness of Status board so so

6

Time wise target and result, line loss status is being marked. Status board is being maintained item wise and element wise. 10

Production status and distribution status of loss can be seen immediately Maintaining cleanness of data sheet in status board 10

6 points

Item wise detail with idle time not monitored on display board

Total 34 marks

taehwa 6 tool motor audit-ii

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