Purpose of internal audit:
Establish a Procedure for the Internal Audit of the Quality Management System and ensure that the Quality Management System confirms all types of internal audits.
Type of Audit in the Automotive Industry:
Quality System Audit:
The organization’s Processes and related results comply with planned arrangements and ensure effective implementation.
Process Audit:
Determination of the effectiveness of the manufacturing process.
Product Audit:
To ensure conformity to product requirements at appropriate stages of production and delivery, verify conformity to all specified requirements, such as dimensions, packaging, functionality, and labeling.
Scope of Internal Audit:
Applicable for below:
- Organization Quality Management System.
- Manufacturing Process Audit
- Product Audit.
Responsibility of Internal Audit:
MR / Qualified auditors are responsible for implementing this procedure.
Procedure Steps:
Quality System Audit :
Prepare a List of Internal Auditors based on their Qualification (minimum graduate or Diploma) for the Audit of QMS, Knowledge & Experience. (Minimum 2 years) With an internal audit certificate.
Prepare an Internal Audit Plan (frequency twice a year), considering all QMS-related processes & activities as well as the results of previous audits.
Prepare an Audit Schedule considering the status & importance of processes & activities and the number of shifts of operation. Ensure the qualified and Approved auditors are used for carrying out the Audit.
Communicate the non-conformance to the concerned auditee for taking appropriate action on the same. The corrective action on the identified Non-conformance is initiated. For non-conformance, the following action is initiated :
(a) Correction done immediately.
(b) The root cause is analyzed within one week & corrective action is implemented according to the type of the root cause.
The target date for implementation is as follows:-
(a) Close all observations within one month.
Summarize all Department Audit findings.
After completion of each Audit Cycle:-
a) Audit Result Summary is prepared and audit results are reviewed.
b) Audit Plan will be reviewed and revised based on audit results (if required.)
c) When internal / External Non-conformity or Customer Complaints occur, the audit frequency shall be appropriately increased or decreased.
Relevant Records:
- List of Internal Quality System Auditors
- Annual Quality System Audit Plan
- Audit Schedule
- System audit checklist and observation sheet.
- Internal quality system audit non-conformance report
- Audit summary report
- Internal audit countermeasure action effectiveness monitoring sheet
Manufacturing Product & Process Audit:
Prepare a List of Internal Process and Product Auditors based on their qualifications, knowledge and experience for the product and process audit. Criteria: Qualification: Min Diploma & Min 2 years experience.
Prepare Process and Product Audit Schedule considering the status & importance of processes and production activities and the number of shifts of operation. Ensure the qualified and approved auditors are used for carrying out the Process and Product Audit.
Prepare the Annual Process and Product Audit Plan, considering all processes and products. Special focus is to be given to the NG Areas of the previous audit, customer-compliant action taken history, and action taken on customer visit observations. Process & product audit frequency is once a year.
Communicate the non-conformance to the concerned auditee for taking appropriate action on the same. The corrective action on the identified non-conformance is initiated as per the following Action.
- Correction done immediately.
- The root cause is analyzed within 4 days
- Corrective action is implemented according to the type of root cause.
Corrective Action:- The target date for implementation is as follows:-
(1) Action related to document revision & preparation within one week.
(2) Action related to imparting in-house/on-the-job training within fifteen days.
(3) Action related to outside support within two weeks. Action related to the system amendment within fifteen days.
Communicate the non-conformance to the concerned auditee for taking appropriate action on the same. The corrective action on the identified Non-conformance is initiated as per the following Action.
a) Correction done immediately.
b) Root cause is analyzed within 4 days
c) Corrective action is implemented according to the type of root cause.
After completion of each Manufacturing Process and Product Audit Cycle:-
a) The Process and product audit result summary is prepared and the audit results are reviewed.
b) The Process and product audit plan will be reviewed based on the results findings if applicable.
After Completion of each Manufacturing Process and Product Audit Cycle:-
a) The Process and product audit result summary is prepared and the audit results are reviewed.
b) The Process and product audit plan will be reviewed based on the results findings if applicable
Relevant Records:
- Manufacturing Process Audit Plan
- Process audit check sheet
- Process audit non-conformity report
- Process audit observation sheet
- Process audit countermeasure action effectiveness monitoring record
Internal Audit Frequency:
| 1 | Quality Management System | Once a year if more than 5 NCs are in an audit, then again re-audit in the next 2 months. |
| 2 | Process Quality Audit | Once a year if more than 5 NCs are in an audit, then again re-audit in the next 2 months. |
| 3 | Product Quality Audit | Once a year if more than 5 NCs in an audit, then again re-audit in the next 2 months. |
Internal Audit Checklist as per IATF 16949
How to do a process audit in the manufacturing industry?