Leadership

Special Audit of Key Characteristics in Control Plan

<LEVEL> 5:Very good(More than expectation) 4:Good(Expectation) 3:Average(Less than Expectation) 2:Bad 1:Very bad(Nothing)
重
み
Evaluation item Questionnaire 付Point Expectation(4point level)
け
Final control How many checking points do you Manufacturing operator clearly knows exact number of checking points, which
(or Control at important have? 重
corresponds to the standard, and also less 10 checking poin ts.
1 process) み
付
け

Do you have Working instruction### Clear working instruction (inspection instruction) with photo (or picture) put in front of
(Inspection instruction) for this? operator

Is this working instruction All checking points in working instruction (inspection instruction) are cohernt with control
(inspection instruction) coherent plan, and matching with process flow diagram
with control plan ?

Are frequency, responsibe person

### Clearly defined boundary sample, frequency, responsibe person, and the action (scrap or
and action in case of Not OK repaire) in case of Not Ok in working instruction (inspection instruction)
clear?

How do you decide your checking

### Checking points should be up-dated from feedback of final customer (warranty), and
points? customer (PPM), and past internal problems.

Daily check sheets(DCS) Do you have DCS for checking Have DCS for daily doccument of all defects coherent with working instruction (inspection
points records including tally 重
instruction)
2 sheet? み
付
け

Do you have graph for dimension

### SPC graph with OK tolerance, process capability with action rule is clearly displayed
check result? somewhere in plant.

Do you have OK first part? ### OK first part is performed every begin ing of shift or every change overs with the evidence
by part and its check sheet

Do you have check sheet for OK

### OK Start of all Poka-yoke and test equipment done with check sheet
Start of Poka-yoke or test
equipment?

Not OK parts control In case of not OK, do you scrap### Operator respect their instruction sheet with boundary sample which is clearly showing
or repair parts? "Scrap or repaire"
3

How do you distinguish scrap and Scrap parts go to red box; repair parts to repair place with identification.
repaire?

In this case, do you feed back to### Immediate feedback to occurrence process, and feedback to GAP leader in case of
occurence process? escalation

In this case, do you stop ### In case of sample check, can clearly identify suspected inventory parts with its traceability
inventory?

How do you repair your parts? ### Working instruction sheet for repair is clearly displayed, including which parts can be
reuse, where they return repaired parts.

Customer feed back Do you have pareto for PPM ### Weekly tracking chart with parato by causes for PPM displayed somewhere in plant
(even from the next process as
4 customer)?

Do you have action plan for Top PDCA exist for Top5 items. Problems completely killed after action.
5?

Incoming parts control Do you have incoming parts They identify incoming parts are OK or NOK.
inspection area in the plant? They can retain parts to be used before inspection is finished.
5

Did you decide checking points Checking points clearly shown in inspection report from supplier
with your suppliers?

Do you have file with periodical Existing file with periodical inspection report from supplier.
inspection report from supplier OK/NOK should be clarified.
for this check result?

Do you periodically audit your Audit plan existing; audit suppliers to improve quality results.
suppliers to prevent quality
concerns?

Total 0

20

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