Process Audit in Automobile Industry

1. You are God to Own your business(Ownership)

2. Know what you know, and know what you don't know (SWOT)

Highlight 2 Mindsets before audit:

Prepared by Bill Yan

Typical Organization Structure

Holistic view 全局观点

B process 一个过程 “the what” “ 什么” A Process

A procedure 一个程序 “the how” “如何” A process Step(PS)

Owner – General Manager/ Plant Manager 负责人 - 总经理 / 厂长

“measure business performance”finance, customer, innovation--KPI测量业绩、财务、顾客、创新

measure efficiency/effectiveness basis for Activity Based Costing 根据成本核算测量活动的效率 / 有效性基础Owner– Process Owner ( Project Leader)

“ the Why” A System

Human Factors— Delivery Personal Quality Job, Beat your plan Everyday

Owner- Operators

--- To define the process for audit

Comparison of the audit types:

Audit Type Audit Subject PurposeSystem Audit Quality system Assessment of the

completeness and effectiveness of the basic requirements

Process audit Product development process/serial production Service development process/Providing the service

Assessment of the quality capability for specific products /product groups and their processes

Product audit Products of services Assessment of quality characteristics

ISO/TS audit is qualitative assessment

Process audit is measurable assessment

More Data & Detailed !

Think different

分层审核 (Layered process Audit)

Close Loop Total QMS Assessment

Process Definition, Structure and Interfaces( WBS and Audit Scope)

Analyze and predigest the process to be more simple process step (PS) and define audit scope

Process breakdown and analysis: 6M1E, 5W2H, 5Whys

PS output( COP)Input

Man Machine

MSA( SPC)

Money (optimize cost)

Materials

Method( FMEA)

Environment

VDA6.3 provide the Questionnaire to every M , It is very helpful to process assessment and reduce process risk.

Base on Value, Data, Factual approach to detailed manage process factor

WhyWhat Who WhereWhenHow long How much

Refer to Quality management principles + AIAG core 5 tools to manage the PS

Execute Process Audit(Highlight)

1. Check last audit report, management review report and CAPA(8D) ---To know overall management level and process capacity expectation

2. Aftersales service data and customer satisfaction performance review ( How to analyze these data and feedback them to Marketing, R&D and Process owner by process?---VOC for DFMEA, an typical Process COPC company for customer satisfaction/CRM)

3. Analyze Value Stream Map(VSM) to know process bottleneck and CIP 4. Analyze Process flow chart and Process control plan(analyze WBS for PS) 5. Typical 2 or 3 products APQP and PPAP review 6. Respect, Time, Patience , Fact, Communication and Result 7. Balance listening and question during audit 8. Balance conflicted process capacity, resource, priority, and interaction of

related processes to optimize system

Measurable Assessment Process– QAKE

Process Specific Audit Questionnaire/Detailed Audit Plan-- On site Audit by track

Benefits of Executing VDA6.3

1. VDA6.3 is best practice for process audit. ISO Audit is qualitative assessmentProcess audit is measurable assessment2. can Identify and distinguish Key process from all process, control key process to reduce the risk .3. Process audit will more focus on result oriented, by KPI to monitor process .4. Measurable and accurate quality system , decrease variance and waste.5. POKA-YOKE and process approach6. More idiographic and more detailed7. Can improve our execute and implement ability , and enhance SOP conduct .8. Compare with TS16949, VDA system more detailed for special quality field .9. Provide professional checklist to 6M1E and process10. eNPI is same of product develop process with VDA6.3 . If introduce VDA6.3 , use the very detailed checklist to avoid and reduce new project risk .also solved more quality issues from headstream.11. Can decrease variance and risk in manufacture process by VDA6.3 audit12. Training Engineers to get full experience and sense about NPI develop process from VDA6.3 checklist and consolidate audit skills 13. In future training supplier about VDA6.3 to enhance RM quality level.

Q&A

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