Siegel Robert Automotive Layered Process Audit Checklist

Process Audit:

Auditor:
All questions are to be answered with a checkmark "Y" or no "N" in the Please write the actual dates in the corresponding
corresponding day's box. Non-conformances are to have corrective action Shift: __________ columns!
recorded in the space provided and identified with the date (MM/DD/YY)
Mon Tues Wed Thurs Fri Sat Sun
These Items Are to be Checked Every
Item No. Audit Area Corrective Action Taken
Audit
Section 1: Operator Instructions
Are operator instructions accessible at the work
1 stations and made available without disruption to the
work being performed?
Do operators undersatnd their work instructions and is
2 the work being performed follow the work instructions
step by step?
Do all operators performing containment activities
3 have work instructions and have they been trained to
the work instructions?
Do all operators have a clear understanding of their
jobs? Do they know the 'right' things to do, are they
4 doing them correctly, and can they demonstrate their
knowledge of what is a quality part?
Are operators filling out required forms and
5 documentation and turning them into their supervisors
per their work instructions?

Section 2: Product Identification, Housekeeping and Workplace Organization

Is all product in the work area properly identified with
1 product status clearly shown per work instructions and
procedures QP-9 & 21.
Are all containment, quarantine and product staging
2 areas physically identified?
Are all work areas maintained in a state of order, well
3 organized with good housekeeping?
 Siegel Robert Automotive Layered Process Audit Checklist

All questions are to be answered with a checkmark "Y" or no "N" in the Please write the actual dates in the corresponding
corresponding day's box. Non-conformances are to have corrective action Shift: __________ columns!
recorded in the space provided and identified with the date (MM/DD/YY)
Mon Tues Wed Thurs Fri Sat Sun
These Items Are to be Checked Every
Item No. Audit Area Corrective Action Taken
Audit
Is suspect product properly identified per work
4 instructions and procedure QP-9.
 Siegel Robert Automotive Layered Process Audit Checklist

All questions are to be answered with a checkmark "Y" or no "N" in the Please write the actual dates in the corresponding
corresponding day's box. Non-conformances are to have corrective action Shift: __________ columns!
recorded in the space provided and identified with the date (MM/DD/YY)
Mon Tues Wed Thurs Fri Sat Sun
These Items Are to be Checked Every
Item No. Audit Area Corrective Action Taken
Audit
Section 3: Process Monitoring and Process Control
Are Process Analysis Boards (PAB) filled out
1 completely and correctly?
Are Process Analysis Board (PAB) charts filled out
2 correctly and up-to-date?

3 Are Process Performance Boards (PPB) maintained?

Is all required information posted on Certified

4 Operation Boards (COB)?
If required, are First Piece Approval tags being used
5 and filled out correctly?
Section 4: Customer Issues and Corrective Actions
Are operators aware of any customer complaints and
1 internal quality issues / concerns?
Are corrective actions for customer complaints
2 implemented and effective? (Obtain customer
complaints from the Quality Manager.)

Are corrective actions for internal quality alerts and

3 concerns implemented and effective?

If rework is being performed, are rework instructions

4 available for the operator and are they being followed?

Have operators reviewed and signed all orange

5 boundary standard tags/parts?

Revision: 9/30/04
 Siegel Robert Automotive Error Proofing Layered Process Audit Checklist

Error Proofing Audit:

Only Qualified Personnel can Perform Error Proofing Verification Audits
Auditor:
All questions are to be answered with a checkmark "Y" or no "N" in the Please write the actual dates in the corresponding
corresponding day's box. Non-conformances are to have corrective action Shift: __________ columns!
recorded in the space provided and identified with the date (MM/DD/YY)
Mon Tues Wed Thurs Fri Sat Sun

Item No. These Items Are to be Checked Every Shift Audit Area Corrective Action Taken

Section 1: General
Are operators aware of the function and importance of
1 any error proofing devices at their station?

Are all error proofing verification parts identified and

2 maintained with due care?

Are all error proofing devices verified per work

3 instructions? Are the verification results recorded?
When error proofing devices fail verification checks,
4 are the proper employees notified? Is this contact
documented? Is there any follow up?

Is there a 'reaction step' to direct operators when error

proofing devices are not functioning? That is, how
5 will the known defect or potential defect be detected in
order to protect the customer in the absence of
automotic error detection?

Are all operators performing error proofing verification

6 checks trained to do so?
Section 1: Work Cell Specific
Will be unique for every work cell containing error
proofing.
 Siegel Robert Automotive Error Proofing Layered Process Audit Checklist

All questions are to be answered with a checkmark "Y" or no "N" in the Please write the actual dates in the corresponding
corresponding day's box. Non-conformances are to have corrective action Shift: __________ columns!
recorded in the space provided and identified with the date (MM/DD/YY)
Mon Tues Wed Thurs Fri Sat Sun

Item No. These Items Are to be Checked Every Shift Audit Area Corrective Action Taken

Revision: 9/30/04
 Assigned Management category
First layer of Management
First layer of Management
Assigned Management personnel
Moulding Shift Engineer
Metalizing Shift Engineer
STI Shift Engineer
Domestic Assly Shift Engineer
Incoming Quality Engineer
Store Incharge
Logistics Incharge
 Department
Audit Assigment Moulding Metalizing STI Assembly Domestic Assembly Incoming Store
Own Department 1 Per Day

Assigned
Management
Category
 Assigned
Management
Category

First Layer of
Supervisors
Management

Second Layer of Plant Staff and Plan

Management Manager

Third Layer of
Corporate SRA
Management

Note: * = if there is no supervisor, the

 Logistics

A sse m b ly
M o ld in g

P la tin g

P a in t

Assigned Assigned
Management Management Audit
Category Personnel Assignment
Mold Supervis or /
Own Department 1 Per Day
Manager
 A sse m b ly
M o ld in g

P la tin g

P a in t
Assigned Assigned
Management Management Audit
Category Personnel Assignment
Mold Supervis or /
Own Department 1 Per Day
Manager

Plating Supervis or /
Own Department 1 Per Day
Manager

Supervisors Paint Supervis or /

Own Department 1 Per Day
Manager
Assembly
Supervis or / Own Department 1 Per D
Manager
Quality Supervisor /
Own Department
Manager
Quality Manager Rotate Departments 1 Per Week
Maintenance
Rotate Departments 1 Per Week
Manger
HR Manager Rotate Departments 1 Per Week
Lean / Training
Rotate Departments 1 Per Week
Coordinator
Assis tant Plant
f Plant Staff and Plant Rotate Departments 1 Per Week
Manager
Manager *Molding Manager Rotate Departments 1 Per Week
*Plating Manager Rotate Departments 1 Per Week
*Paint Manager Rotate Departments 1 Per Week
*As s embly
Rotate Departments 1 Per Week
Manager
Plant Manager Rotate Departments 1 Per Week
Shipping Manager Rotate Departments 1 Per Week
VP of Quality Rotate Departments 1 Per Quarter
VP of Operations Rotate Departments 1 Per Quarter
Corporate SRA
Quality Sys tems
Rotate Departments 1 Per Quarter
Engineer

e is no supervisor, then the area manager shall be considered the first layer of manageme
 P la tin g

P a in t

A sse m b ly

D o ck A u d its
 D ock A u d i
A sse m b ly
P la tin g

P a in t

er Day

1 Per Day

1 Per Day

1 Per Day

1 Per Week
1 Per Week

1 Per Week
1 Per Week

1 Per Week

1 Per Week
1 Per Week
1 Per Week
1 Per Week

1 Per Week
1 Per Week
1 Per Quarter
1 Per Quarter
1 Per Quarter

t layer of management.