By the end of this 2-day _practical _course & workshop participants will be able to plan, perform and report the results of manufacturing process (product) audits in their own organization and at supplier premises.
The purpose is to empower quality engineers, internal auditors, SQA and other personnel to conduct manufacturing process (product) audits in an effective manner and meet in full the expectations of the aerospace Primes. Such audits are now becoming a mandatory requirement of NPI (New Product Introduction) and APQP (Advanced Product Quality Planning) – and are an ‘expectation’ of the soon-to-be-published AS9145 standard.
The main focus of the 2-day session is practicality. Consequently, the majority of the time is given over to workshops and actual supervised manufacturing process audits (including one-on-one coaching).
The on-site course commences with a review of existing arrangements (if any) for conducting manufacturing process (product) audits and has the following objectives –
- to implement a vigorous; and customized; process for conducting manufacturing process (product) audits that suits an organization’s products and manufacturing processes (including ‘special’ processes)
- to provide the required personnel training and ‘coaching’ to ensure that selected quality engineers and internal auditors are equipped to conduct manufacturing process (product) audits in an effective manner
- to meet the expectations of AS9145 to ensure that products continue to be produced in the manner described in the initial PPAP (Production Part Approval Process) submission – and authorized updates
- to identify opportunities for improvement by capturing ideas for changes in production methods from shop-floor personnel and instigating corrective action to address shortcomings in the implementation of authorized manufacturing methods
All courses commence with a review of existing arrangements (if any) for conducting manufacturing process (product) audits
- Introduction to ‘process-based’ auditing
- Explanation of the ‘different types’ of audit –
- quality management system audits
- manufacturing process (product) audits
- FAIRs (product audit
- Understanding of the purpose of criteria for manufacturing process audits with special reference to their role in the NPI (New Product Introduction) and APQP (Advanced Product Quality Planning) mandated in AS9145
- Establishing an audit programme for manufacturing process audits that includes internal production and subcontract activities, to verify compliance to current planned arrangements
- Prioritizing the manufacturing process audit programme based on product and process risk
- Determining if the resources and controls used to transform inputs into outputs are effective and comply with requirements –
- tooling, equipment, work environment and gauges (Gauge R&R)
- process flow chart, floor plan layout, FMEA, control plan
- drawings, specifications, set-up/work instructions, test/inspection plans
- Product preservation, logistics, identification, traceability (serialization), configuration management, inspection status, SPC charts, etc.
- Determining that KC (Key Characteristics) are being addressed –
- confirmation of a significant production process run
- capability studies completed (Cpk values established)
- ongoing use of appropriate SPC methods for control
- conformity with AS9103 requirements (if applicable)
- Determining that FAIR (First Article Inspection Report) requirements have been met – and that FAIRs remain ‘current’
- conformity with AS9102 requirements (if applicable)
- Investigation of the need/use for LAIR (Last Article Inspection Report) at the end of a production run or for ‘transfer-of-work’ purposes – as applicable
- Investigation of the need/use for reduced inspection of variables – as applicable
- Investigation of the need/use of sample inspection as a means of product acceptance – as applicable
- Review of the PPAP (production product approval process) or equivalent documentation and related records
- Preparations for a manufacturing process audit –
- identification of documents and records
- identification of process controlled conditions (inputs, outputs, transformation activities; goals and interfaces); the structure of processes (process mapping) and other sources of information
- Development of customized manufacturing process audit questionnaires –
- use of TEC’s generic aerospace/defence manufacturing process audit questionnaire
- customization of the questionnaire to suit the organization’s products, processes (including ‘special processes’), work environment and customers
- Undertaking a supervised manufacturing process audit –
- conducting the audit
- recording the results
- containment actions (as required)
- continual improvement
- Documenting the manufacturing process (product) audit
- generating audit findings –
- identifying nonconformities
- identifying ideas for changes in production methods
- writing effective NCRs (nonconformity reports)
- preparing audit conclusions
- feedback to the auditee (presenting the closing meeting)
- audit follow-up & closure
- writing a succinct audit report
- Extended Q & A session
Who should attend
Quality engineers and internal auditors needing to conduct manufacturing process (product) audits in their own organization and at supplier premises.
Other individuals who have found this course useful are SQA personnel, six sigma practitioners, team leaders and supervisors in aerospace/defence organizations, who are looking to broaden their awareness of quality issues relating to the design and operation of manufacturing processes in order to understand how they can improve overall business effectiveness.
TEC's knowledge and experience of performing formal manufacturing process (products) audits has been gained from working with clients in the UK, Europe, USA and Russia – the automotive, aviation, defence and rail sectors. During these assignments we have ensured that our client’s personnel are empowered to undertake effective manufacturing process audits to ensure conformity with current manufacturing methods, and to identify opportunities for improvement that can be implemented under controlled conditions.
Our ‘know-how’ is available to your organization through this new 2-day practical course and workshop. Using one-on-one coaching, we ensure that participants will learn in a structured manner how to use a battery of powerful manufacturing process (product) audit techniques and tools.