IATF 16949 audits | How do I: Audit the production process of set up verification

Summary

This video script outlines an audit of a manufacturing setup process, focusing on the machine setter's role. The auditor questions the setter about the setup and verification process, but is criticized for asking too many close-ended questions and inefficiently using audit time. The video highlights the importance of open-ended questions for gathering objective evidence and suggests that auditors should manage their time effectively, possibly auditing other processes while waiting for setup completion.

Takeaways

• 🔍 The video focuses on auditing the manufacturing process setup and verification.
• 👷 The auditor interviews a machine setter who has been in the role for ten years.
• 🛠️ The machine setter explains the process of changeover and setup.
• 📝 The control plan is reviewed, emphasizing the importance of checking the last off from the previous run.
• 🕒 The auditor waits for the first off sample, which will take approximately 30 minutes.
• 🤔 The auditor asks too many closed questions, which limits the machine setter's responses.
• 🕰️ The auditor spends an extended period observing the setup, which may not be the most effective use of time.
• 🔄 The video suggests the auditor should have checked other machines or processes during the setup time.
• 📋 The ITF 16949 requirements related to job setup and verification are mentioned.
• 🔄 The auditor could have also inquired about triggers for job setup after unplanned shutdowns.
• 📈 The key learning points emphasize the use of open-ended questions and effective time management during audits.

Q & A

What is the main focus of the video?

The video focuses on auditing the organization's manufacturing process, specifically the setup and verification process.

What is the role of the person being interviewed in the video?

The person being interviewed is a machine setter who has been working at the company for ten years, with the last five years involved in setting up machines.

How is the changeover process initiated in the manufacturing process?

The changeover process is initiated by production planning informing the machine setter to pull down once the previous batch is finished.

What is the first task the machine setter performs during the setup process?

The first task the machine setter performs is to take out the old tooling from the machine and replace it with the new tooling for the next batch.

What is the purpose of the first off verification?

The purpose of the first off verification is to ensure that the new setup is correct and the machine is producing parts within specifications.

According to the control plan, what should the setter check before returning the tool to storage?

According to the control plan, the setter should check the last off from the previous run before returning the tool to storage.

What is the expected time frame for the machine setter to complete the setup process?

The expected time frame for the machine setter to complete the setup process is approximately 30 minutes.

What could be considered ineffective about the auditor's approach in the video?

The auditor's approach is considered ineffective because they ask too many closed or leading questions and spend time waiting for the setup to be completed without auditing other processes.

What ITF 16949 requirements are related to the auditing process shown in the video?

The ITF 16949 requirements related to the auditing process in the video are 8.5.1.3 verification of job setup and 8.5.1.4 verification after shutdown.

Why is it important for auditors to use open-ended questions during an audit?

It is important for auditors to use open-ended questions to obtain sufficient objective evidence and to encourage detailed responses that can reveal more about the process being audited.

What should auditors do to make effective use of their audit time?

Auditors should make effective use of their audit time by auditing multiple processes or machines simultaneously or following audit trails while waiting for critical steps in the process to be completed.