Product Audit Planning

As far i as i know, the product audit is an audit of the manufactured product based on each manufactuyring stage.
So if the process are:

Injection Process -> Assembly Process - > Counting & Packing -> Delivery Preparation

The sample of the product audit shall took sample of each process and compare them to the customer requirements right?

But, does the sample has to be the same part? Or we may took different sample part of each process according to the running manufacturing schedule?

Fadhilah Cholish Azhari said:

As far i as i know, the product audit is an audit of the manufactured product based on each manufactuyring stage.
So if the process are:

Injection Process -> Assembly Process - > Counting & Packing -> Delivery Preparation

The sample of the product audit shall took sample of each process and compare them to the customer requirements right?

But, does the sample has to be the same part? Or we may took different sample part of each process according to the running manufacturing schedule?

Click to expand...

So to be simple, should the sampling plan be like this:

Injection Process -> Assembly Process - > Counting & Packing -> Delivery Preparation
(Part A) (Part A) (Part A) (Part A)

or can it be like this?

Injection Process -> Assembly Process - > Counting & Packing -> Delivery Preparation
(Part A) (Part B) (Part C) (Part D)

I'm no auditor, but if the process is the same, why could it not be like the 2nd statement?

I'd probably opt for the 1st statement anyway, for continuity. Part B probably has a different assembly process than part A; How is this going to look on your report? (Referencing different parts, for different parts of the process)

Fadhilah Cholish Azhari said:

So to be simple, should the sampling plan be like this:

Injection Process -> Assembly Process - > Counting & Packing -> Delivery Preparation
(Part A) (Part A) (Part A) (Part A)

or can it be like this?

Injection Process -> Assembly Process - > Counting & Packing -> Delivery Preparation
(Part A) (Part B) (Part C) (Part D)

Click to expand...

You could sample X item per product before shipping and going backwards for each of them.
Do you follow a procedure for product audit or do you follow a check list as per your customer requirement? What do you check to be effective in your business?

qusys said:

You could sample X item per product before shipping and going backwards for each of them.
Do you follow a procedure for product audit or do you follow a check list as per your customer requirement? What do you check to be effective in your business?

Click to expand...

So we plan to set the process/product audit object to be the product that was running at the time the audit was performed.

If we chose the option 1, how do we confirm if the parts was processed according to the control plan if the manufacturing prcess is already done/over. Actually we could check the recent manufacturing records. But i feel like that was not really hit the audit point, because the auditor did not actually see the actual process if the paramater/controls implemented are according to the control plan or not.

If we choose the 2nd option, we can confirm the actual running manufacturing process, is it according to the control plan or cust. requirements or no. And the auditor may also really compare the standards and the actual process occurring. But the weakness is there is no continuity of audited parts.
The 2nd option also offer us to audit more type of process/product (ex. Assembly : Automated assembly & Manual/Jig Assembly) at the same time without checking the other process (because other processes of the products are similar to other products).

So, which the option you would recommend?

qusys said:

You could sample X item per product before shipping and going backwards for each of them.
Do you follow a procedure for product audit or do you follow a check list as per your customer requirement? What do you check to be effective in your business?

Click to expand...

Well, currently our customers does not requiring us specific for procedures (e.g VDA, or else). But currently, we conduct product audit based on customer requirement (such as Drawing, FMEA, Control Plan, Inspection Standard, Limit/standard sample).

So, in order to establish a proper and suitable product/process audit in our company. I would like to have a suggestion

Fadhilah Cholish Azhari said:

Well, currently our customers does not requiring us specific for procedures (e.g VDA, or else). But currently, we conduct product audit based on customer requirement (such as Drawing, FMEA, Control Plan, Inspection Standard, Limit/standard sample).

So, in order to establish a proper and suitable product/process audit in our company. I would like to have a suggestion

Click to expand...

Process/Product audits are two different things. The thread is about product audit, so why not focus on this first?

I would suggest that you write a procedure for internal audit and then put sections for system/process/product audits in your procedure. Since we are talking about product audit the question is how you define which product to audit and why? For instance if there's a design change taking place it is wiser to conduct product audit shortly after design change has been completed. Or if there's a non-conformity, which is repeating you could audit the product. Or if you have a new product put in place and are in the process of ramp-up also it is wiser to audit this product. There are many factors to consider. You audit the product based on customer drawing and if it is a full product audit that means 100% against specifications on the drawing + any customer requirements and customer specific requirements. Apart from that you should make a plan for the product audit taking in consideration all risk factors your manufacturing environment. I think this is a good starting point and then you can work your way up towards better procedure and audit plan.

Fadhilah Cholish Azhari said:

So we plan to set the process/product audit object to be the product that was running at the time the audit was performed.

If we chose the option 1, how do we confirm if the parts was processed according to the control plan if the manufacturing prcess is already done/over. Actually we could check the recent manufacturing records. But i feel like that was not really hit the audit point, because the auditor did not actually see the actual process if the paramater/controls implemented are according to the control plan or not.

If we choose the 2nd option, we can confirm the actual running manufacturing process, is it according to the control plan or cust. requirements or no. And the auditor may also really compare the standards and the actual process occurring. But the weakness is there is no continuity of audited parts.
The 2nd option also offer us to audit more type of process/product (ex. Assembly : Automated assembly & Manual/Jig Assembly) at the same time without checking the other process (because other processes of the products are similar to other products).

So, which the option you would recommend?

Click to expand...

Why not the third option — follow one part thru the entire process? It may take a few days or weeks or however long it takes to complete a part.

I always pick one part number (product) and follow all the process steps using the Control Plan. I mark up the control plan for any product/document errors or failure to follow the steps.