FORM NO: PH/QA/R/10

POLYHOSE ENTERPRISE LLP REV. NO: 01

MANUFACTURING PROCESS AUDIT CHECKLIST REV DATE: 02/11/2019

PROCESS FLOW CHART NO: Part No: Audited by :

CONTROL PLAN NO: Part description: Audit date :
PFMEA No: Auditee: Audit type Surveillance

S.No Check points Characteristics Spec Actual C NC Observation

Incoming inspection is carried out -

Sampling inspection done based on standards/

Self approved
Incoming

For raw material TC are crossed verified by testing

1
in outside lab

Identification of rejected material are stored

seperately stored

Are equipments used of inspection is calibrated

Shearing Machine
A

PH/WI/06

Plasma PH/PDR/D/02-B
B

Laser PH/PDR/D/02-A
C

Bandsaw cutting PH/WI/04

Machining

Iron worker PH/WI/05

E

Bending
F

PH/WI/02

Page 1 Process audit

S.No Check points Characteristics Spec Actual C NC Observation

Incoming inspection is carried out

Drilling PH/WI/03
G

Rolling PH/WI/01
H
Incoming

1 Availabilityof flow meter and gauges

Wire diameter 1.2mm

Protective sheilding on welding area -

Welding

3 Welding Amp Volt Gas flow

150 - 180
3 to 5mm 20 - 22 V 10-15 lpm
A
Welding parameters
180 - 220
5 to 8 mm 22 - 24 V 10-15 lpm
A

220 - 240
More than 8mm 22 - 24 V 10-15 lpm
A

Shot blasting

Steel grit G-18

Shot blasting

4 Shot blasting parameters Steel shot S- 330

Mixing ratio
1:1
(Grit : Shot)

Current 16-19 Amps

Page 2 Process audit

S.No Check points Characteristics Spec Actual C NC Observation

Incoming inspection is carried out Primer Painting

Apply viscosity 20-22 sec

Pressure 3.5 - 4.5 bar

Painting
Incoming

5
1 Painting parameters
Finish Painting

Apply viscosity 18-22 sec

Pressure 4 - 6 bar

Is the FMEA available and is it reviewed & updated

6
following quality concerns?

Does the FMEA adhere to the process flow and is it

7
linked to the processing sequence numbers?

Are there corrective actions against high risk-priority-

8
numbers?

9 Are control plans are recorded, updated and verified?

Does the control plan adhere to the process flow and to

10 PFMEA and is it linked to the processing sequence
numbers?

Is the Control Plan reviewed and updated following

11
quality concerns?

Are appropriate sampling and control methods

12 identified, including the application of SPC where
required?

Is appropriate inspection, measuring and test

13
equipment identified?

Page 3 Process audit

S.No Check points Characteristics Spec Actual C NC Observation

Incoming
Does the reaction plan inspection is carriedresponses
define appropriate out in
14 the event of out of control, non-capable, and/or
nonconforming conditions?
Incoming

15 Do Cp, Cpk, values meet requirements?

1

16 Is SPC data analyzed for continuous improvement?

Are in process inspections conducted per the control

17 plan and/or other documents and do records
demonstrate conformity to requirements?

Are final inspections conducted per the control plan

18 and do records demonstrate conformity to
requirements?

Is all MME necessary for process controls are available,

19 adequate, calibrated and working in good operating
condition?

Does the Control Plan address all "special" product

20 - - - -
characteristics & process parameters?

Is there a calibration system available for both company

21 - - - -
owned & personal gauges & is calibration up to date?

Are Measurement System Analyses conducted on

22 special characteristics' measurement systems? Do the - - - -
results satisfy the acceptance criteria?

Is first piece inspection required and do records

23 - - - -
demonstrate conformity to requirements?

Are in process/sampling inspections conducted as per

24 - - - -
the control plan?

Page 4 Process audit

S.No Check points Characteristics Spec Actual C NC Observation

25 Incoming
Where applicable, areinspection is carried out
effective Poke-Yokes utilized? - - - -

26 Are there appropriately marked places for scrap? - - - -

Incoming

1
27 Is internal scrap & rework monitored? - - - -

Are SOP's available at all

28 - - - -
operations?

29 Are the SOP's followed by the operators? - - - -

Do the SOP's reference the part

30 - - - -
name, part number, and part revision?

31 Is there a complaint log?

32 Is a disciplined problem solving method used (8D/JDI)

Manufacturing process including the appropriate

33
sampling of the shift handover?

34 Ensure PFMEA covers all rework process?

35 Ensure PFMEA addressed all continual improvements?

36 Ensure fixture verificaton & validation?

37 Ensure FMEA ranking as per requirement.

Auditor signature: Auditee signature :

Page 5 Process audit