Process Audit Preparation "Turtle Diagram" Process Control

Machine tooling Equiment With Who? HR

Tools
Machines , Equipmemnts ,Instruments Machine setup,Job setup, process Control
charts,Product inspection, CPK,Reworks

Customer oriented Process

Inputs Outputs
Production Planning Tools production out put,
validation, Machine , maintenance Process control Variationreduction,On time delivery,Better
CPk,Wastage reduction
productivity , Cutters , Monitoring
Curing Processs.

How? Procedures / Work Instructions preformance / Results

Production plan versus Acheived ,Error
detectabilty , in-process yeild, increase in output
Control Plan,Operator instructions , per employee ,process responsible for delay
Appearence , sample , Work intsructions
 Process Audit Preparation "Turtle Diagram" Example: Goods receiving
With What?
IT Hard- & Software
Packaging
Materials handling equipment
Storage space
Transportation
MFG / PRO system
Inputs
Purchase orders
Supplier shipping documents
Receiving schedule
How?
Approved supplier records
Purchasing process
Corr. / prev. action procedures
Document & Record control
Product approval process
Personnel safety
With Who?
Competent people
Induction/ training records
Purchasing people
Logistic planning
Process
Outputs
Conform purchased product
Goods receiving
delivered on-time
MFG / PRO up to date
(Support Processes) What Results?
Logistics processes Analysis of data
Doc & Rec Control Delivery schedule performance
Manufacturing process Premium freight
Stores processes Inventory turns
Purchasing process Obsolete product
 Process Audit Preparation "Turtle Diagram" Example: Contract review
With What? Market inputs With Who?

Market survey Cost Break down analysis,Risk & Sales Manager ,Marketing dept
Contingency managment

Process
Inputs Outputs

Enquiry,Quotations,Offers,Critical Contract Review Review report,Order

stock, accepptance,Contractual agreement

How? What Results?

Contract review procedures (9001:2015) Analysis of data,revenue ,actual versus plan

Delivery schedule performance
Document & Record control Price revisions , Premium freight
approval process Inventory turns
 Process Audit Preparation "Turtle Diagram" Example: APQP
With What? Systems With Who?

Cost breakdown analyst,Competent Project

Design / CAD /CAE Software management skills with Product design &
process design knowledge people

Customer oriented Process

Inputs Outputs
Timely Launch,minimum PPM after
Drawings ,Specifications,Programme APQP launch,Approved PPAP files
needed dates, Supplier
manual/Intsructions,Price target,Volume
target , CPK target

How? (Support Processes) What Results?

APQP Procedures , APQP Change / test plan,Time required for engineering

action procedures Manual , Supplier Manual, change ,Production plan schedule,No of engg
SPC/MSA,PPA,CSR Manual, Chaneds after design review, monitoring,Quality,
Document & Record control Cost of Poor quality,
Product approval process MTBR
Personnel safety
 Process Audit Preparation "Turtle Diagram" Production Planning
Machine tooling Equiment With Who? HR
Tools, Moulding Machines , Cutters , Curing
Processs Cost breakdown analyst,Competent Project
management skills with Product design &
process design knowledge people

Customer oriented Process

Inputs Outputs
Stageise Inspection, Final Inspections ,
Controlled Outsurced acticities,
Production Planning , CSR Production Planning
Drawings ,Specifications,Programme
needed dates, Intsructions,Volume target ,
CPK target

How? Procedures / Work Instructions preformance / Results

Monitoring,test results, Inspection
reports,Quality,Internal Rejections , Machine break
action procedures down reports ,
Cost of Poor quality,
Document & Record control MTBR,
Product approval process
Personnel safety
 Process Audit Preparation "Turtle Diagram" Process Control
Machine tooling Equiment With Who? HR
Tools
Machines , Equipmemnts ,Instruments Machine setup,Job setup, process Control
charts,Product inspection, CPK,Reworks

Customer oriented Process

Inputs Outputs
Production Planning Tools production out put,
validation, Machine , maintenance Process control Variationreduction,On time delivery,Better
CPk,Wastage reduction
productivity , Cutters , Monitoring
Curing Processs.

How? Procedures / Work Instructions preformance / Results

Production plan versus Acheived ,Error
detectabilty , in-process yeild, increase in output
Control Plan,Operator instructions , per employee ,
Appearence , sample , Work intsructions
 Process Audit Preparation "Turtle Diagram" Delivery Procedure

Delivery Mode With Who? HR

Mode of transport
Skilled personel with packing knowledge

Customer oriented Process

Inputs Outputs
Delivery Plan,Customer Identification, DC , Batch numberTag,
requirements Delivery Procedure Address, TCs , and other necessary
Documents,transport Logs

How? Procedures / Work Instructions preformance / Results

Packing & Delivery procedure Ontime delivery Monitoring

late delivery details , unpacked details, Stores
details.Errors , transit damage details.
 Process Audit Preparation "Turtle Diagram" Conrrol of non conforming product

Delivery Mode With Who? HR

Mode of transport
Skilled personel with packing knowledge

Customer oriented Process

Inputs Outputs
Delivery Plan,Customer Conrrol of non conforming Identification, DC , Batch numberTag,
requirements product Address, TCs , and other necessary
Documents,transport Logs

How? Procedures / Work Instructions preformance / Results

Packing & Delivery procedure Ontime delivery Monitoring

late delivery details , unpacked details, Stores
details.Errors , transit damage details.