Ts16949 Internal Audit (Jul05) Nc Rs
- 1. QMS ISO/TS 16949 INTERNAL AUDIT
- 2. AUDIT TREND MATRIX * INDICATES, REPORT AWAITED 99 17 14 1 11 56 Total 1 NIL NIL NIL 1 NIL 75 9 3 1 NIL NIL 5 74 11 3 1 1 3 3 73 4 NIL 3 NIL NIL 1 72 3 * 1 NIL NIL 2 69 7 NIL 1 NIL 3 3 68 11 NIL 2 NIL NIL 9 66 21 3 3 NIL 1 14 65 32 8 2 NIL 3 19 64 Total Jul-05 Sep-04 May-04 Feb-04 Jan-04 Unit
- 3. FOCUS AREA 3 1 1 1 SYSTEM NOT FOLLOWED (HOLD/APQP/MSA) 1 1 LATEST MIP NOT FOLLOWED 1 1 REJECTION ANALYSIS NOT DONE 1 1 MICRO LEVEL PLAN INADEQUATE 17 3 3 3 8 TOTAL 1 1 PROCESS VALIDATION NOT DONE 3 1 2 INSPECTION NOT EVIDENCED 3 1 1 1 NO TRAINING IDENFITICATION/RECORDS 4 1 3 CONTROL PLAN UPDATION INADEQUATE TOTAL U74 U73 U65 U64 DISCREPANCIES
- 4. UNIT 64 INSPECTION 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). FIRST INSPECTION CARRIED OUT BY THE OPERATOR NOT RECORDED IN THE FIRST INSPECTION REPORT. FIRST OFF REPORT NOT EVIDENCED FOR THE PART WHICH IS UNDER PRODUCTION. 64/03/03 TRAINING 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. ON THE JOB TRAINING HAS BEEN GIVEN ON THE DAY OF PERSON JOINTED TO THE UNIT AND BUT RECORD NOT UPDATED. NO EVIDENCE OF PROVIDING ON THE JOB TRAINING TO THE OPERATOR PRIOR TO WORKING ON THE MACHINE INDEPENDENTLY. 64/03/02 CONTROL PLAN WHEN EVER ANY CHANGE/ERROR FOUND BY THE SUPERVISOR (MANUFACTURING) WILL INFORM IMMDIATELY TO SUPERVISOR (TECHNICAL) WITHOUT MANUAL CORRECTION. ALTERNATE TOOLS AND ERROR IDENTIFIED BY THE SUPERVIOSR (MANUFACTURING) HAS BEEN WRITTEN MANUALLY AND NOT INFORMTED TO THE SUPERVISOR (TECHINCAL) FOR UPDATION. MANUAL CORRECTION MADE IN THE CONTROL PLAN OP.40, TO INDICATE ALTERNATIVE FIXTURES AND NOT INDICATED IN THE AMENDMENT 64/03/01 FOCUS AREA CORRECTIVE ACTION ROOT CAUSE OBSERVATIONS REF.
- 5. UNIT 64 INSPECTION CALIBRATION 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. 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. 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. 64/03/06 PROCESS VALDIATION CONTROL PLAN WILL BE UDPATED ONLY AFTER VALIDATION REPORT IS COMPILED AND THE SAME WILL BE ENSURED BY THE UNIT HEAD. PROCESS RE-VALIDATION HAS BEEN CARRIED OUT, BUT FORMAL REPORT WAS NOT COMPILED. IN CHROME PLATING PROCESS, THE PROCESS (<S>) PARAMETERS FOUND CHANGED. PROCESS RE-VALIDATION IS NOT EVIDENT FOR THE SAME 64/03/05 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. THIS IS APPLCIABLE ONLY FOR THE P.NO.29320723 (QUALIS/TAVERA), HENCE NOT INDICATED IN THE COMMON CONTROL PLAN. 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. 64/03/04 FOCUS AREA CORRECTIVE ACTION ROOT CAUSE OBSERVATIONS REF.
- 6. UNIT 64 REJECTION ANALYSIS 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. TAGET HAS BEEN FIXED DURING REJECTION REVIEW. THIS IS ACHIEVED OVER A PERIOD OF TIME NO EVIDENCE OF INITIATING ACTIONS TO ACHIEVE PLANNED RESUTLS (SET TARGET) REF. REJECTION AND REWORK TREND. TARGET FIZED 64/03/08 CONTROL PLAN ALL THE CORRECTIVE ACTION IDENTIFIED (TEMPORARY OR PERMENANT) DURING ANALYSIS WILL BE UPDATED IN THE CONTROL PLAN AND ENSURED BY UH. CORRECTIVE ACTIONS INDENTIFIED IS TEMPORARY, HINCE NOT UPDATED IN THE CONTROL PLAN. 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. 64/03/07 FOCUS AREA CORRECTIVE ACTION ROOT CAUSE OBSERVATIONS REF.
- 7. UNIT 65 SYSTEM NOT FOLLOWED ALL MSA STUDIES WILL BE PLANNED AND CONDUCTED AS PER PLAN. ONLY R&R STUDIES WERE CONDUCTED AND NOT PLANNED FOR OTHER STUDIES LIKE BIAS, LINEARITY & STABILITY BIAS, LINEARITY AND STABILITY STUDIES ARE NOT EVIDENCED. 65/03/03 CONTROL PLAN WHENEVER THE CONTROL PLAN UPDATED, THE ADEQUACY WILL BE CHECKED AND AUTHORIZING BY THE UNIT HEAD. TYPOGRAPHICAL ERROR. INSPECTION FREQUENCY NOT INLINE WIHT CONTROL PLAN (EVERY 4 HOURS INSPECTED INSTEAD EVERY1 HOUR FOR RETRACTED DIMN.) 65/03/02 TRAINING TRAINING IDENTIFICATION WILL BE TAKEN FROM COMPETENCY GAPS AND SEPARATE LIST AS PER FORMAT (FM/HRM/T&D/03, SEP-03). COMPETENCY GAPS HAS BEEN TAKEN PRIMARY IDENTIFICATION, HENCE NO SEPARATE LIST MAINTAINED. THERE IS NO EVIDENCE OF TRAINING IDENTIFICATION FOR THE SUPERVISORY EMPLOYEES. 65/03/01 FOCUS AREA CORRECTIVE ACTION ROOT CAUSE OBSERVATIONS REF.
- 8. UNIT 73 SYSTEM NOT FOLLOWED HOLD SYSTEM WILL BE FOLLOWED, EVEN IF SEGGRIGATED AND CLEARED ON THE DAY OF AUDIT ITSELF. ON THE DAY OF AUDIT ITSELF THE SUSPECTED LOTS WERE SEGGRIGATED, HENCE NOT KEPT UNDER "HOLD". PRODUCT NOT KEPT UNDER "HOLD" FOR NONCONFORMANCE FOUND DURING PRODUCT AUDIT 73/03/03 SYSTEM NOT FOLLOWED LATEST MATERIAL INSPECTION PLAN (MIP) WILL BE UPDATED IN THE COMPUTER MATERIAL ACCOUNTING SYTEM (INGRESS) AND FOLLOWED. LATEST MATERIAL INSPECTION PLAN (MIP) NOT UPDATED IN THE COMPUTER MATERIAL ACCOUNTING SYTEM (INGRESS) THE SAMPLE SIZE RECIVED AS PER THE MIC FOR THE MATERIAL INSPECTION IS NOT AS PER THE LATEST MATERIAL INSPECTION 73/03/02 INSPECTION OBSERVATION RECORD WILL BE MAINTAINED IN BOOK FORM TO RECORD OBSERVATIONS IN ORDER AVOID MISSING DURING HANDLING. SALT SPRAY TEST OBSERVATIONS RECORD WAS IN LOOSE SHEET FORM AND THE SAME WAS MISSED DURING HANDLING / FILING. EVIDENCE OF THIS TEST BEING DONE IS NOT AVAILABLE. (PAD SALT SPRAY TEST) 73/03/01 FOCUS AREA CORRECTIVE ACTION ROOT CAUSE OBSERVATIONS REF.
- 9. UNIT 74 SYSTEM INADEQUATE ALL THE ACTIVITIES AS PER PROJECT APQP WILL BE INCORPORATED IN THE INTENAL MICRO LEVEL PLAN AND FOLLOWED. SAME PROJECT APQP AND TOOLING PLAN HAS BEEN FOR DESIGN DEVELOPMENT OF PRODUCT/PROCESS. HENCE NO SEPARATE PLAN USED FOR PROCESS DESIGN AND DEVELOPMENT. 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 74/03/03 SYSTEM NOT FOLLOWED FOR MODIFIED PRODUCT, ITERNAL PLAN WILL BE PREPARED FOR CHANGE CHILD PART DEVELOPMENT AND IMPLEMENTED AS PER THE PLAN. ONLY PAD ASSEMBLIES IS CHANGE IN THE EXISTING PRODUCT, HENCE NO NEW PRODUCT ROUTING FOLLOWED. THERE IS NO EVIDENCE FOLLOWING PROJECT APQP, PPAP APPROVAL, AND GETTING APPROVAL/WAIVER FOR DIMENSIONAL DEVIATION FOR THE PRODUCT DISPATCHED TO CUSTOMER. 74/03/02 TRAINING TRAINING IDENTIFICATION WILL BE TAKEN FROM COMPETENCY GAPS AND SEPARATE LIST AS PER FORMAT (FM/HRM/T&D/03, SEP-03). COMPETENCY GAPS HAS BEEN TAKEN PRIMARY IDENTIFICATION, HENCE NO SEPARATE LIST MAINTAINED. THERE IS NO EVIDENCE OF TRAINING NEED IDENTIFICATION AGAINST THE COMPETENCY GAPS. 74/03/01 FOCUS AREA CORRECTIVE ACTION ROOT CAUSE OBSERVATIONS REF.