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QMS ISO/TS 16949

INTERNAL AUDIT
AUDIT TREND MATRIX
Unit Jan-04 Feb-04 May-04 Sep-04 Jul-05 Total
64 19 3 NIL 2 8 32
65 14 1 NIL 3 3 21
66 9 NIL NIL 2 NIL 11
68 3 3 NIL 1 NIL 7
69 2 NIL NIL 1
*
3
72 1 NIL NIL 3 NIL 4
73 3 3 1 1 3 11
74 5 NIL NIL 1 3 9
75 NIL 1 NIL NIL NIL 1
Total 56 11 1 14 17 99
* INDICATES, REPORT AWAITED
FOCUS AREA
DISCREPANCIES U64 U65 U73 U74 TOTAL
CONTROL PLAN UPDATION INADEQUATE 3 1 4
NO TRAINING IDENFITICATION/RECORDS 1 1 1 3
INSPECTION NOT EVIDENCED 2 1 3
SYSTEM NOT FOLLOWED (HOLD/APQP/MSA) 1 1 1 3
REJECTION ANALYSIS NOT DONE 1 1
PROCESS VALIDATION NOT DONE 1 1
MICRO LEVEL PLAN INADEQUATE 1 1
LATEST MIP NOT FOLLOWED 1 1
TOTAL 8 3 3 3 17
UNIT 64
R
E
F
.

OBSERVATIONS ROOT CAUSE CORRECTIVE ACTION FOCUS AREA
6
4
/
0
3
/
0
1

MANUAL CORRECTION
MADE IN THE CONTROL
PLAN OP.40, TO
INDICATE
ALTERNATIVE
FIXTURES AND NOT
INDICATED IN THE
AMENDMENT
ALTERNATE TOOLS AND
ERROR IDENTIFIED BY
THE SUPERVIOSR
(MANUFACTURING) HAS
BEEN WRITTEN
MANUALLY AND NOT
INFORMTED TO THE
SUPERVISOR (TECHINCAL)
FOR UPDATION.
WHEN EVER ANY
CHANGE/ERROR FOUND BY
THE SUPERVISOR
(MANUFACTURING) WILL
INFORM IMMDIATELY TO
SUPERVISOR (TECHNICAL)
WITHOUT MANUAL
CORRECTION.
CONTROL
PLAN
6
4
/
0
3
/
0
2

NO EVIDENCE OF
PROVIDING ON THE JOB
TRAINING TO THE
OPERATOR PRIOR TO
WORKING ON THE
MACHINE
INDEPENDENTLY.
ON THE JOB TRAINING HAS
BEEN GIVEN ON THE DAY
OF PERSON JOINTED TO
THE UNIT AND BUT
RECORD NOT UPDATED.
WHEN EVER NEW EMPLOYEES
JOINED IN THE UNIT, ON THE
JOB TRAINING WILL BE GIVEN
AND THE TRAINING RECORD
WILL BE UPATED
IMMEDIATELY AND THE SAME
WILL BE ENSURED BY THE
UNIT HEAD.
TRAINING
6
4
/
0
3
/
0
3

FIRST OFF REPORT NOT
EVIDENCED FOR THE
PART WHICH IS UNDER
PRODUCTION.
FIRST INSPECTION
CARRIED OUT BY THE
OPERATOR NOT
RECORDED IN THE FIRST
INSPECTION REPORT.
FIRST OFF INSPECTION WILL
BE CARRIED OUT AND
RECORDED IN THE FIRST OFF
INSPECTION REPORT
IMMEDIATELY AND THE SAME
WILL BE ENSURED BY THE
SUPERVISOR
(MANUFACTURING).
INSPECTION
UNIT 64
R
E
F
.

OBSERVATIONS ROOT CAUSE CORRECTIVE ACTION FOCUS AREA
6
4
/
0
3
/
0
4

TIME AND VOLTAGE OF
ELECTRO CLEAN, CHROME
ETCH AND CHROME
PLATING THICKNESS ARE
IDENTIFIED AS "<S>" IN
THE FMEA IS NOT
ADDRESSED IN THE
CONTROL PLAN.
THIS IS APPLCIABLE ONLY
FOR THE P.NO.29320723
(QUALIS/TAVERA), HENCE
NOT INDICATED IN THE
COMMON CONTROL PLAN.
IF ANY CUSTOMER SPECIFIC
REQUIREMENTS IDENTIFIED
DURING NEW PART ADDITON TO
THE COMMON CONTROL PLAN
THE SPECIAL INDICATION WILL
BE MADE AND FOLLOWED.
CONTROL
PLAN
6
4
/
0
3
/
0
5

IN CHROME PLATING
PROCESS, THE PROCESS
(<S>) PARAMETERS FOUND
CHANGED. PROCESS RE-
VALIDATION IS NOT
EVIDENT FOR THE SAME
PROCESS RE-VALIDATION
HAS BEEN CARRIED OUT,
BUT FORMAL REPORT
WAS NOT COMPILED.
CONTROL PLAN WILL BE
UDPATED ONLY AFTER
VALIDATION REPORT IS
COMPILED AND THE SAME WILL
BE ENSURED BY THE UNIT
HEAD.
PROCESS
VALDIATION
6
4
/
0
3
/
0
6

MONITORING AND
MEASUREMENT NOT
CARRIED OUT AS PER THE
REQUIREMENTS. E.G.
1). ELECTRO CLEAN
VOLTMETER FOUND NOT
WORKING
2).LEVER DIAL
(REF.64LD08) IS NOT
CALIBRATED.
1). "V" BLOCK CONTACT
WITH FLIGHT BAR WAS
NOT THERE, IT WAS
RECTIFIED IMMEDIATELY
BY CLEANING THE "V"
BLOCK
2).THIS PARTICULAR
INSTRUMENT WAS NOT
USED FOR LAST 15 DAYS,
HENCE DUE DATE NOT
NOTICED BY THE USER.
1). "V" BLOCK CLEANING
FREQUENCY WILL UPDATED IN
THE WORK INSTRUCTION AND
FOLLOWED.
2).LIST OF INSTRUMENT WITH
DUE DATE ARE DISPLAYED AT
RECEIVING INSPECTION AND
REVIEWED DAILY BY THE RI
INCHARGE AND INSTRUMENTS
WILL BE SENT TO STANDARD
ROOM FOR CALIBRATION.
INSPECTION
CALIBRATION
UNIT 64
R
E
F
.

OBSERVATIONS ROOT CAUSE CORRECTIVE ACTION
FOCUS
AREA
6
4
/
0
3
/
0
7

NO EVIDENCE OF INDICATING
CONTAINMENT ACTION WITH
RESPONSIBILITY IN
CORRECTIVE ACTION COLUMN
OF CONTROL PLAN TO ENSURE
100% CLAMPING TO ORIGINAL
POSITION BY THE OPERATOR.
CORRECTIVE ACTIONS
INDENTIFIED IS
TEMPORARY, HINCE NOT
UPDATED IN THE CONTROL
PLAN.
ALL THE CORRECTIVE
ACTION IDENTIFIED
(TEMPORARY OR
PERMENANT) DURING
ANALYSIS WILL BE
UPDATED IN THE
CONTROL PLAN AND
ENSURED BY UH.
CONTROL
PLAN
6
4
/
0
3
/
0
8

NO EVIDENCE OF INITIATING
ACTIONS TO ACHIEVE PLANNED
RESUTLS (SET TARGET) REF.
REJECTION AND REWORK
TREND. TARGET FIZED
TAGET HAS BEEN FIXED
DURING REJECTION
REVIEW. THIS IS ACHIEVED
OVER A PERIOD OF TIME
DAILY ANALYSIS BEING
CARRIED OUT BY CFT
AND REVIEWED DAILY
IN THE DAILAY
MANAGEMENT REVIEW
MEETING BY UNIT
HEAD. MONTHLY IN THE
REJECTION & REWORK
MANAGEMENT REVIEW
BY THE TOP
MANAGEMENT.
REJECTION
ANALYSIS
UNIT 65
R
E
F
.

OBSERVATIONS ROOT CAUSE CORRECTIVE ACTION FOCUS AREA
6
5
/
0
3
/
0
1

THERE IS NO EVIDENCE OF
TRAINING IDENTIFICATION FOR
THE SUPERVISORY EMPLOYEES.
COMPETENCY GAPS HAS
BEEN TAKEN PRIMARY
IDENTIFICATION, HENCE
NO SEPARATE LIST
MAINTAINED.
TRAINING
IDENTIFICATION WILL BE
TAKEN FROM
COMPETENCY GAPS AND
SEPARATE LIST AS PER
FORMAT
(FM/HRM/T&D/03, SEP-03).
TRAINING
6
5
/
0
3
/
0
2

INSPECTION FREQUENCY NOT
INLINE WIHT CONTROL PLAN
(EVERY 4 HOURS INSPECTED
INSTEAD EVERY1 HOUR FOR
RETRACTED DIMN.)
TYPOGRAPHICAL
ERROR.
WHENEVER THE
CONTROL PLAN
UPDATED, THE
ADEQUACY WILL BE
CHECKED AND
AUTHORIZING BY THE
UNIT HEAD.
CONTROL
PLAN
6
5
/
0
3
/
0
3

BIAS, LINEARITY AND STABILITY
STUDIES ARE NOT EVIDENCED.
ONLY R&R STUDIES
WERE CONDUCTED AND
NOT PLANNED FOR
OTHER STUDIES LIKE
BIAS, LINEARITY &
STABILITY
ALL MSA STUDIES WILL
BE PLANNED AND
CONDUCTED AS PER
PLAN.
SYSTEM NOT
FOLLOWED
UNIT 73
R
E
F
.

OBSERVATIONS ROOT CAUSE CORRECTIVE ACTION FOCUS AREA
7
3
/
0
3
/
0
1

EVIDENCE OF THIS TEST
BEING DONE IS NOT
AVAILABLE. (PAD SALT SPRAY
TEST)
SALT SPRAY TEST
OBSERVATIONS RECORD
WAS IN LOOSE SHEET FORM
AND THE SAME WAS MISSED
DURING HANDLING /
FILING.
OBSERVATION RECORD
WILL BE MAINTAINED IN
BOOK FORM TO RECORD
OBSERVATIONS IN ORDER
AVOID MISSING DURING
HANDLING.
INSPECTION
7
3
/
0
3
/
0
2

THE SAMPLE SIZE RECIVED
AS PER THE MIC FOR THE
MATERIAL INSPECTION IS
NOT AS PER THE LATEST
MATERIAL INSPECTION
LATEST MATERIAL
INSPECTION PLAN (MIP)
NOT UPDATED IN THE
COMPUTER MATERIAL
ACCOUNTING SYTEM
(INGRESS)
LATEST MATERIAL
INSPECTION PLAN (MIP)
WILL BE UPDATED IN THE
COMPUTER MATERIAL
ACCOUNTING SYTEM
(INGRESS) AND
FOLLOWED.
SYSTEM NOT
FOLLOWED
7
3
/
0
3
/
0
3

PRODUCT NOT KEPT UNDER
"HOLD" FOR
NONCONFORMANCE FOUND
DURING PRODUCT AUDIT
ON THE DAY OF AUDIT
ITSELF THE SUSPECTED
LOTS WERE SEGGRIGATED,
HENCE NOT KEPT UNDER
"HOLD".
HOLD SYSTEM WILL BE
FOLLOWED, EVEN IF
SEGGRIGATED AND
CLEARED ON THE DAY OF
AUDIT ITSELF.
SYSTEM NOT
FOLLOWED
UNIT 74
R
E
F
.

OBSERVATIONS ROOT CAUSE CORRECTIVE ACTION FOCUS AREA
7
4
/
0
3
/
0
1

THERE IS NO EVIDENCE OF
TRAINING NEED
IDENTIFICATION AGAINST THE
COMPETENCY GAPS.
COMPETENCY GAPS HAS
BEEN TAKEN PRIMARY
IDENTIFICATION, HENCE NO
SEPARATE LIST MAINTAINED.
TRAINING
IDENTIFICATION WILL
BE TAKEN FROM
COMPETENCY GAPS
AND SEPARATE LIST
AS PER FORMAT
(FM/HRM/T&D/03, SEP-
03).
TRAINING
7
4
/
0
3
/
0
2

THERE IS NO EVIDENCE
FOLLOWING PROJECT APQP,
PPAP APPROVAL, AND GETTING
APPROVAL/WAIVER FOR
DIMENSIONAL DEVIATION FOR
THE PRODUCT DISPATCHED TO
CUSTOMER.
ONLY PAD ASSEMBLIES IS
CHANGE IN THE EXISTING
PRODUCT, HENCE NO NEW
PRODUCT ROUTING
FOLLOWED.
FOR MODIFIED
PRODUCT, ITERNAL
PLAN WILL BE
PREPARED FOR
CHANGE CHILD PART
DEVELOPMENT AND
IMPLEMENTED AS
PER THE PLAN.
SYSTEM NOT
FOLLOWED
7
4
/
0
3
/
0
3

MICRO LEVEL TIMING PLAN
DERIVED FROM PROJECT APQP
PLAN NOT CAPTURING ALL
THE APPLICABLE ACTIVITIES
OF PE&MSE, ALSO MFG.
PROCESS DESIGN AND
DEVELOPMENT NOT
EVIDENCED
SAME PROJECT APQP AND
TOOLING PLAN HAS BEEN
FOR DESIGN DEVELOPMENT
OF PRODUCT/PROCESS.
HENCE NO SEPARATE PLAN
USED FOR PROCESS DESIGN
AND DEVELOPMENT.
ALL THE ACTIVITIES
AS PER PROJECT APQP
WILL BE
INCORPORATED IN
THE INTENAL MICRO
LEVEL PLAN AND
FOLLOWED.
SYSTEM
INADEQUATE

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