IATF 16949 audits | How do I: Audit the production process of set up verification
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
🔍 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
💡Manufacturing Process
💡Machine Setter
💡Setup Verification Process
💡Control Plan
💡First Off
💡ITF 16949
💡Objective Evidence
💡Open Audit Questions
💡Job Setup
💡Unplanned 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.
Transcripts
[Music]
this video focuses on auditing the
organization's manufacturing process and
it's covering the auditing of the setup
verification process the auditor is
questioning the machine setter watch
this video and identify whether the
auditor does this audit effectively good
morning good morning my name can you
explain to me a raw yeah I'm a machine
setter so I've worked here for about ten
years started off as an operator last
five years I've been involved in setting
the tones into the machine okay and can
you explain the set of process to me
so women need to do a changeover we were
informed by production planning so
production would pull me down once they
finished the previous batch my job is to
take that all out of the machine we have
to change the very quite work for
therefore the new tool and then when I
finish the setup then we run through our
first off verification
the can so looking at your control plan
here yeah yeah it states last off from
the previous run is checked by the
setter prior to the tool being returned
to store is that correct yeah yeah we do
last off
and then it states the new tool set up
the process parameters and the first
object can you show me the first off
which is probably going to be about
another 30 minutes before it before I
finish the setup on this machine so at
the moment I have no first of the sample
if you went away that's okay but it's
gonna take me probably another 30
minutes
no problem I'll sit here and wait okay
I'll carry on right so let's summarize
the good thing is the oddity is on the
shop floor to audit the set up
verification and it spends time
understanding the role of the person
doing the job setup however the order to
ask too many clothes or leading
questions allowing the setter to answer
yes or allowing the setter to answer no
without providing any relevant objective
evidence also it is an effective to use
time stand-in watching the set are
finishing the set up for 30 minutes
the auditor should always have either
sample the effectiveness of the setup on
another machine or follow the audit
trails to other production processes or
machines and then they can return back
to see the first of verification at this
machine the applicable ITF 16949
requirements related in this video would
be eight point five point one point
three verification of job setup the
auditor could have also questioned the
setter on what triggers another job
setup for example after an unplanned
shutdown this will be relate to ATF
16949 requirement eight point five point
one point four verification after
shutdown so let's summarize the key
learning points auditor should always
utilize open audit questions so they can
get sufficient objective evidence
ordered should make effective use of
audit time while standing and observing
is good
there will be limited value for standing
and watching the setter complete the
full set up which in this case could
last for up to 30 minutes for more
information visit the website in the
description and don't forget to
subscribe
[Music]
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