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

IATF 16949 Auditing

25 Sept 201904:03

Summary

TLDRThis 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.

Outlines

00:00

🔍 Auditing Manufacturing Process

The video script describes an audit of a manufacturing organization's setup and verification process. The auditor meets a machine setter with ten years of experience, who explains the changeover process from one batch to another. This involves removing the old tooling and setting up new ones, followed by a first-off verification. The control plan is reviewed, confirming that the last off from the previous run is checked before the tool is returned to storage. The script highlights the auditor's effectiveness in understanding the process and the role of the machine setter but suggests improvements in questioning technique and time management. The ITF 16949 requirements related to job setup verification are mentioned, emphasizing the importance of open questions to gather objective evidence and efficient use of audit time.

Mindmap

Keywords

💡Auditing

Auditing in the context of the video refers to the systematic examination of an organization's manufacturing process to ensure it meets specific standards or requirements. It is a critical part of quality management and is used to identify areas for improvement. In the video, auditing is the main activity being performed by the auditor who is questioning the machine setter about the setup and verification process.

💡Manufacturing Process

The manufacturing process is the sequence of steps involved in producing a good or service. It is a key concept in the video as the auditor is focused on evaluating this process to ensure it adheres to quality standards. The video specifically discusses the setup and verification stages of this process.

💡Machine Setter

A machine setter is an individual who prepares and adjusts machines or equipment for operation. In the video, the machine setter is being interviewed by the auditor to understand the setup process. The role of the machine setter is crucial as they are directly involved in the setup of the manufacturing process.

💡Setup Verification Process

The setup verification process is a series of checks and balances to ensure that a machine is correctly set up before production begins. It is highlighted in the video as a critical step in the manufacturing process. The auditor is interested in this process to confirm that it is being carried out correctly.

💡Control Plan

A control plan is a document that outlines how key processes will be controlled and by whom. It is mentioned in the video as the auditor reviews it with the machine setter. The control plan is a tool used to ensure that the setup process is followed correctly and is a part of the quality management system.

💡First Off

First off refers to the first piece of a product produced after a machine setup. It is used to verify that the setup is correct and the machine is producing the product to specification. In the video, the machine setter mentions that they will run a first off verification after setting up the machine.

💡ITF 16949

ITF 16949 is a quality management system standard for the automotive industry. It is mentioned in the video as the standard that the manufacturing process should adhere to. The auditor is ensuring that the setup and verification process complies with this standard.

💡Objective Evidence

Objective evidence is information that can be verified for its accuracy and validity, often used in auditing to confirm compliance or effectiveness. The video suggests that the auditor should seek objective evidence rather than just yes/no answers to ensure a thorough audit.

💡Open Audit Questions

Open audit questions are inquiries that encourage detailed responses rather than simple yes or no answers. They are recommended in the video as a method for the auditor to gain more comprehensive information from the machine setter about the setup process.

💡Job Setup

Job setup refers to the process of preparing a machine or equipment for a specific task or job. It is a central theme in the video as the auditor is auditing this process to ensure it meets the required standards. The script mentions that the auditor should verify the job setup.

💡Unplanned Shutdown

An unplanned shutdown is when a machine or process stops unexpectedly. The video suggests that the auditor could inquire about the procedures following such an event, which would require a new job setup. This is related to the ITF 16949 requirement for verification after a shutdown.

Highlights

The video focuses on auditing the organization's manufacturing process.

It covers the auditing of the setup and verification process.

The auditor questions the machine setter about their role and responsibilities.

The machine setter has been working for ten years and is involved in setting up the machine.

The setup process involves a changeover informed by production planning.

The machine setter explains the process of removing the old tooling for the new one.

The first off verification is mentioned as part of the setup process.

The control plan is checked by the setter prior to the tool being returned to store.

The auditor waits for the first off sample to be available.

The auditor spends time on the shop floor to audit the setup verification.

The order of questions by the auditor is criticized for being too closed or leading.

The auditor is advised to utilize open-ended questions for better objective evidence.

The auditor is suggested to make effective use of audit time instead of just observing.

The ITF 16949 requirements related to job setup verification are mentioned.

The auditor could have questioned the setter on triggers for another job setup.

The video provides key learning points for auditors on how to conduct effective audits.

The video encourages the use of open audit questions to gather sufficient evidence.

The video concludes with a call to action for more information and subscription.