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Guide to Manufacturing Process Audits

Guide to Manufacturing Process Audits

Most manufacturing businesses use process audits to keep up with ever-changing tasks of ensuring adherence to routine operating conditions, standards, and expectations. 

Process audits come in various forms, from completing simple checklists to deeper and broader processes into specific manufacturing operations. During a process audit, the auditor records, aggregates, and categorizes potential non-conformances. Afterward, the operations staff will then perform corrective actions based on the audit findings.

Process audits are a critical part of ensuring that lines are working properly and enforcing quality and safety. It also helps pinpoint non-conformances at the source. This article will discuss process audits to show you why you should implement this process into your business operations.

What is Manufacturing Process Audits?

Manufacturing process audits are a type of quality assurance that is performed to ensure that manufacturing processes conform to the company’s quality standards. In addition, these audits aim to identify non-conformances and correct them before they cause problems downstream.

Process audits can assess any type of manufacturing process, from simple assembly line processes to complex multi-step processes. This type of audit usually focuses on one specific process at a time but can also assess the entire manufacturing operation.

Why are Process Audits Important?

Process audits are important because they help ensure that products are manufactured according to its quality standards. These audits can also help identify potential problems with the manufacturing process to be corrected before they cause defects in the finished product.

Process audits are also important because they help to ensure that manufacturing processes are running smoothly and efficiently. By identifying bottlenecks and inefficiencies in the manufacturing process, process audits can help improve overall productivity.

Finally, process audits are important because they can help to ensure compliance with regulatory requirements. By auditing the manufacturing process, companies can identify areas where they may be out of compliance and take corrective actions to fix the issue.

Benefits of Process Audits

Process audits offer several benefits to manufacturing companies. Some of the most important benefits are the following:

  • Helps ensure that products are manufactured according to company quality standards
  • Helps identify potential problems with the manufacturing process so they can have corrective action before they cause defects in the finished product
  • It Helps ensure that manufacturing processes are running smoothly and efficiently
  • Helps ensure compliance with regulatory requirements
  • Helps improve overall productivity

 

As you can see, process audits offer many benefits to manufacturing companies. If you are not already conducting process audits at your company, we recommend that you start doing so as soon as possible. 

Doing so will help to ensure that your products are of the highest quality and that your manufacturing process is running properly. Additionally, conducting process audits will help you ensure compliance with all relevant regulatory requirements.

Types of Manufacturing Process Audits (And Why They Don’t Always Work)

While essential, process audits are not always successful in identifying and correcting problems with a manufacturing process. In some cases, this is due to the type of audit conducted. Here are three common types of manufacturing process audits and why they may not always be effective:

Paper-based Checklist Audits

You can simplify a process audit into a simple checklist. These checklists help you ensure that each step in the process is being followed and there are no deviations. 

The problem with this type of audit is that it relies on human memory, which can be fallible. Additionally, this type of audit does not explain why a deviation from the standard occurred.

Card-based Audits

Some organizations think audits take too long and emphasize an overburdened supervisor, line leader, or engineer. So they create an audit card that the process operator completes to alleviate this.

This type of audit can be more effective than a paper-based checklist audit because it does not rely on human memory. Additionally, it can provide some insight into why a deviation from the standard occurred. However, this type of audit still has its limitations. For example, it does not provide a complete picture of the manufacturing process and can only identify problems during the shift conducted.

Layered Process Audits

Often, the best way to conduct a process audit is to use a combination of different types of audits. This approach, known as layered process audits, helps ensure that all aspects of the manufacturing process are audited and that any identified problems can be quickly corrected.

Layered process audits usually involve conducting multiple paper-based checklist audits, card-based audits, and/or process mapping audits during each shift. This approach helps identify problems early and correct them before they cause defects in the finished product.

While conducting process audits is important, choosing the right type of audit for your organization is also important. Doing so will help to ensure that you are getting the most out of your process audits and that your manufacturing process is running smoothly and efficiently.

How to Get the Most Out Of Your Audits Using Digital Apps

At this point, you already know that paper-based process audits are impractical because of the following reasons:

  • Paper is prone to error.
  • Cards are time-consuming to manage
  • Paper-based data is hard to analyze and aggregate

 

Fortunately, there are easy means of running your audits, with digitizing being one of the most effective. By using or creating a process audit application, you can eliminate the flaws of paper, gather data in real-time, and streamline your auditing process.  

Create a Process Audit Checklist App Using DataMyte

With the DataMyte Digital Clipboard, you can create, perform, and manage audits using your company’s very own audit checklist app. DataMyte’s app builder offers various tools and features that will help you create your very own process audit checklist app:

  • You can easily add or remove questions from your checklist.
  • You can create custom fields for each question on your checklist.
  • It can add photos, videos, and other attachments to your checklist.
  • You can share your checklist with others in your organization.
  • You can view all of the data that has been collected in one place.
  • It can export your data to a CSV file for further analysis.

 

With DataMyte, you can create a process audit checklist app tailored to your organization’s needs. Visit our website to learn more!

 

Conclusion

Now that you know how important manufacturing process audits are, it’s time to put it into practice by starting today! Process audit checklist apps are among the easiest ways to digitize your entire process. And with DataMyte, you can easily create a process audit checklist app that will help you streamline your manufacturing process. 

 

 

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