FORM NO: PH/QA/R/10
POLYHOSE ENTERPRISE LLP REV. NO: 01
MANUFACTURING PROCESS AUDIT CHECKLIST REV DATE: 02/11/2019
PROCESS FLOW CHART NO: Part No: Audited by :
CONTROL PLAN NO: Part description: Audit date :
PFMEA No: Auditee: Audit type Surveillance
S.No Check points Characteristics Spec Actual C NC Observation
Incoming inspection is carried out -
Sampling inspection done based on standards/
Self approved
Incoming
For raw material TC are crossed verified by testing
1
in outside lab
Identification of rejected material are stored
seperately stored
Are equipments used of inspection is calibrated
Shearing Machine
A
PH/WI/06
Plasma PH/PDR/D/02-B
B
Laser PH/PDR/D/02-A
C
Bandsaw cutting PH/WI/04
Machining
Iron worker PH/WI/05
E
Bending
F
PH/WI/02
Page 1 Process audit
S.No Check points Characteristics Spec Actual C NC Observation
Incoming inspection is carried out
Drilling PH/WI/03
G
Rolling PH/WI/01
H
Incoming
1 Availabilityof flow meter and gauges
Wire diameter 1.2mm
Protective sheilding on welding area -
Welding
3 Welding Amp Volt Gas flow
150 - 180
3 to 5mm 20 - 22 V 10-15 lpm
A
Welding parameters
180 - 220
5 to 8 mm 22 - 24 V 10-15 lpm
A
220 - 240
More than 8mm 22 - 24 V 10-15 lpm
A
Shot blasting
Steel grit G-18
Shot blasting
4 Shot blasting parameters Steel shot S- 330
Mixing ratio
1:1
(Grit : Shot)
Current 16-19 Amps
Page 2 Process audit
S.No Check points Characteristics Spec Actual C NC Observation
Incoming inspection is carried out Primer Painting
Apply viscosity 20-22 sec
Pressure 3.5 - 4.5 bar
Painting
Incoming
5
1 Painting parameters
Finish Painting
Apply viscosity 18-22 sec
Pressure 4 - 6 bar
Is the FMEA available and is it reviewed & updated
6
following quality concerns?
Does the FMEA adhere to the process flow and is it
7
linked to the processing sequence numbers?
Are there corrective actions against high risk-priority-
8
numbers?
9 Are control plans are recorded, updated and verified?
Does the control plan adhere to the process flow and to
10 PFMEA and is it linked to the processing sequence
numbers?
Is the Control Plan reviewed and updated following
11
quality concerns?
Are appropriate sampling and control methods
12 identified, including the application of SPC where
required?
Is appropriate inspection, measuring and test
13
equipment identified?
Page 3 Process audit
S.No Check points Characteristics Spec Actual C NC Observation
Incoming
Does the reaction plan inspection is carriedresponses
define appropriate out in
14 the event of out of control, non-capable, and/or
nonconforming conditions?
Incoming
15 Do Cp, Cpk, values meet requirements?
1
16 Is SPC data analyzed for continuous improvement?
Are in process inspections conducted per the control
17 plan and/or other documents and do records
demonstrate conformity to requirements?
Are final inspections conducted per the control plan
18 and do records demonstrate conformity to
requirements?
Is all MME necessary for process controls are available,
19 adequate, calibrated and working in good operating
condition?
Does the Control Plan address all "special" product
20 - - - -
characteristics & process parameters?
Is there a calibration system available for both company
21 - - - -
owned & personal gauges & is calibration up to date?
Are Measurement System Analyses conducted on
22 special characteristics' measurement systems? Do the - - - -
results satisfy the acceptance criteria?
Is first piece inspection required and do records
23 - - - -
demonstrate conformity to requirements?
Are in process/sampling inspections conducted as per
24 - - - -
the control plan?
Page 4 Process audit
S.No Check points Characteristics Spec Actual C NC Observation
25 Incoming
Where applicable, areinspection is carried out
effective Poke-Yokes utilized? - - - -
26 Are there appropriately marked places for scrap? - - - -
Incoming
1
27 Is internal scrap & rework monitored? - - - -
Are SOP's available at all
28 - - - -
operations?
29 Are the SOP's followed by the operators? - - - -
Do the SOP's reference the part
30 - - - -
name, part number, and part revision?
31 Is there a complaint log?
32 Is a disciplined problem solving method used (8D/JDI)
Manufacturing process including the appropriate
33
sampling of the shift handover?
34 Ensure PFMEA covers all rework process?
35 Ensure PFMEA addressed all continual improvements?
36 Ensure fixture verificaton & validation?
37 Ensure FMEA ranking as per requirement.
Auditor signature: Auditee signature :
Page 5 Process audit
