What are the most effective quality audits for the automotive industry?

In my experience and what I have seen , product audit is done to confirm that whether product is meeting intended purpose, specifications and customer expectations. More importantly based on agreement, criticality and regulatory requirements , product audit can be conducted internally by manufacturer or by third party auditor or even by customer or regulator authority to ensure compliance and gain confidence. Product audit can support in proactively identifying and preventing various defects , ensuring compliance and improving customer satisfaction, which eventually fosters continuums improvement and excellence.

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A process audit is a structured review of processes to identify where improvements can be made. Process audits help to implement QMS by improving the efficiency & effectiveness of operations by identifying areas where improvements are needed. In product manufacturing, a process audit is a systematic assessment of the activities, procedures, & methods involved in the production, to evaluate their effectiveness, efficiency, and compliance. Based on the agreement , criticality and regulatory requirements , a process audit can be conducted internally, or by a third-party auditor, Customer , or a regulatory authority. This audit can proactively support help identify & eliminate NCs, reduce variation, optimize resources, and enhance quality .

What is most important outcome from the Process audit? Not the number of the non-conformities (NCs) but the number of the opportunities for improvement (OFIs) that Company can use for making it's QMS more efficient and sustainable. I used to face auditors who were focused on finding NCs rather than pointing on OFIs. That is much worther than doing the audit in a formal way and not trying to find anything at all.

Process auditing and I think it would be better to invite people with technical skills as co-auditors in different processes and sub-processes.

System audit for QMS has a few key success factors: - Keep the straightforward checklist that would help you to go through the major requirements - Focus on positive outcomes (OFIs) rather negatives (NCs). There is no need to punish the Company - Follow the timings. The task is huge so you had better keep an eye on the time schedule.

What I learned following my past encounters when comes to automotive. IATF has been stressed out the ways of contribution’s between vendors & manufacturer while understanding the requirements. Therefore, one should must involve themselves to their suppliers & by auditing them prior will be the best practice to get rid of any potential losses in future. Continuation to that this will strengthen the relationship in all formats(Supplier-Manufacturer-Customer). Essentials need to validate such as: * Supplier assets. * Ethical data exchange & Control. * Employees literacy & Development. * Opportunity for improvements.

Supplier audit is one of the key audits for the Company who has Suppliers. it does not matter whether it is initial or annual audits. Supplier might has impelemented a changes last year so you better review then in order to be 100% sure there is still a compliance towards the Supplier Quility Agrement.

Different type of audits and Objectives... There are three types of audits. 1) First party audits 2) Second party audits 3) Third party audits Each type of audit plays an important role in ensuring Quality, Compliance, and Improvement within an Org. They collectively contribute to Operational excellence, Risk mitigation, Sustenance of an Organizational processes, and meeting Customer specific requirements. Adding all the quality audits in these 3 categories and defining the scope and objectives will help auditors to do the audit effective. Following are few more quality audits to consider: Pokayoke verification audits 5S Audits Regulatory/Compliance Audits Product Layout Audits Line readiness Audits PPAP audits & Follow up Audits etc.

During my initial days at work, an audit was conducted by top management on Safety, Quality and Productivity. The audit was done weekly on all these three parameters. There was no predefined check sheet. The days were fixed for the audit as Monday safety audit, Thursday productivity audit and on Saturday quality audit. All previous observations are verified first and then the next audit was done. There was a significant improvement in the shop floor by these specific audits.

Audits are a life line to get going and improving continuously... Daily, weekly, monthly and so on audits are for looking at things differently and challenging the status quo along with compliance related lags and more efficient usages. Daily audits with one out of SQPCDM as focus for that day brings new pace and accelerates momentum of improvements and being compliant while making work a joy...means danger free, dirt free, fatigue free, defect free, waste free and compliant...