IATF 16949 9.2.2.3 - Manufacturing process audits
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QualityWorld1
Starting to get Involved
Are we supposed to internal audit manufacturing/ Production every year? Standard does not mandate it to be performed annually. All Processes need to be audited in a 3-year cycle. Am I missing something??
Management system:
over a three year period...based on annual plan (i.e. can't wait until Dec of year three to do any audits...i.e. some audit activity every year).
Manufacturing process:
over a three year period...based on annual plan (i.e. can't wait until Dec of year three to do any audits...i.e. some audit activity every year). Yes required to audit 'all' processes by the end of each three year period.
Hope this helps.
Be well.
Consider that your programming should be prioritized based on performance, risks, changes, results, criticality, etc.
And the scope must include all work shifts
Hello,
I was given the task to create a procedure for "Control Plan Audits" to comply with this clause. I am kind of lost about what the requirements are and where to start. Anyone can provide example of how you and your organization perform the "Control Plan Audits". If you could share an example, a diagram or a procedure that I can use to guide me, that would be truly appreciated. Any kind of advice/suggestions are more than welcome.
Thank you!
I was given the task to create a procedure for "Control Plan Audits" to comply with this clause. I am kind of lost about what the requirements are and where to start. Anyone can provide example of how you and your organization perform the "Control Plan Audits". If you could share an example, a diagram or a procedure that I can use to guide me, that would be truly appreciated. Any kind of advice/suggestions are more than welcome.
Thank you!
Ashland78
Quite Involved in Discussions
As @Pjservan said you can do this over a 3 year period. I work at a big 3 company, however my company ships to Toyota, and other customers that require IATF. So I am pretty confident that as we have 6 key production types as long as we audit 2 each year, including a sample of customer concerns (8-d situations) (helps meet the risk portion), and the CQI Assessments (we have CQI-9, 12, 15 and most recently 14 added). That covers us for manufacturing process audits (MPA). But we compare the PFD to the PFMEA to the PCP when doing the 6 key production types.
5S and Layered process audits count as MPA but are more for daily-weekly production.
A certified consultant told me that I can create a process where someone gets the control plan from part "X" and audit all the steps defined on the control plan. Then the next month do the same for part "Y" and so on for 3 years as along as audit during all shifts. He said that this will be our compliance for Product Audits and Manufacturing Process Audits. The questions here is, is it true that I can comply with both type of audits by auditing the control plan?
You can use the control plan for both types of audits. However, one focuses the manufacturing process, i.e.; how are you making the product. The other focuses on other things, but can overlap. We pick our product audit items, off the dock because we hit packaging, labeling, etc. Our manufacturing audits focus on the production floor and follows the part thru those steps.
toniriazor
Involved In Discussions
Was this task assigned by your manager or requested by your customer?
It is strange to have a specific procedure for Control Plan audits. For instance I think it is better to have a procedure for internal audits and when you perform the audit you decide what tools to use. My approach was to have the control plan in my hands or in my computer and then audit the manufacturing processes with it. Other colleagues had a different approach and did not use it directly , but afterwards to compare their findings against the control plan. The typical scope of internal audit procedure would be to audit operations processes to cover the manufacturing part, input related to customer specific requirements, special processes/customer oriented processes, any customer complaints, handling of design change.
If such procedure already exists you can simply update it stating that "Relevant Control Plan must be used during the manufacturing process audit".
Anyone else who can provide input or correct me if my logic is wrong, as I am not an expert on the subject and don't want to mislead the colleague.
So IATF 9.2 identifies 3 types of audits required: Quality mgmt system audits, manufacturing process audits, and product audits. It further defines Mfg. process audit in 9.2.2.3 and requires use of the control plan (among other docs) in the audit.
So we look at it three ways. First from a system level -- we look at our manufacturing process overall. Are we meeting requirements, mostly identification and paperwork, but not part specific. For the manufacturing process audit, we dial into a specific part number and use the control plan to audit against. Likewise, the product audit is part specific.
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