Annex A

Process Audit Preparation “Turtle Diagram”

With What?
(Materials/Equipment)
•Computerized system
•Fax
Inputs
•BOM
•Purchasing Requisition
•Customer requirement
(approve-source) Supplier selection/ development
•Regulatory requirement
•Production schedule
With Who?
(Competence/Skills/Training)
•Trained purchasing staff
•Supplier development teams
•Financial authorized person
Process Output
•Contour purchased product
Purchasing (7.4)
conform to spec.
Monitoring of supplier •On-time receiving
Purchasing process

How? With What Key Criteria?

(Methods/ Procedures/Techniques) (Measurement/Assessment)
•Purchasing procedure •Cost of poor material receiving
•Supplier selection •Timeliness (on-time)
•Supplier performance monitoring •Material/ product quality
•Supplier development process •Procedure material shortage
•E-mail •Premier freight
Annex B
Process Audit Preparation “Turtle Diagram”
With What?
(Materials/Equipment)
•Material, component
•Production machine/equipment With Who?
•Molding, pressing, assembly (Competence/Skills/Training)
•Inspection tools, gauges •Trained operator
•Assembly jigs •QC
•Component parts

Inputs
•QMS requirement Process Output
•Defrost grill conform to
•Feedback of information Defrost grill assembly
from service customer requirement/
•Customer requirement regulatory
•Special characteristic
•Production schedule
•Delivery schedule
•Regulatory requirement
•Quality target
How?
(Methods/ Procedures/Techniques) With What Key Criteria?
•Control Plan (Measurement/Assessment)
•Work instruction for job set up verification •PPM
•Inspection/ Test instruction •Quality Cost
•SPC •Delivery performance
•Error proofing •Time for return product test/ analysis
•Procedure of stamping, molding and problem solving
•Response time
•Cpk
Annex C
Process Audit Preparation “Turtle Diagram”
With What?
(Materials/Equipment) With Who?
•Purchasing data base (Competence/Skills/Training)
•BOM •Trained purchasing
•Staff
Inputs
•Delivery schedule
•Supplier schedule
•Approved supplier list
•Customer requirement Process
•Approved source Output
Purchasing •On-time delivery
•Purchase requisition (75% component of 7.4.1) •Conforming purchased
•Regulatory requirement Are outsource from
•Records of supplier performance product
2 suppliers
•Product requirement (design record)
•Production schedule
•Acceptance criteria With What Key Criteria?
How? (Measurement/Assessment)
•Timeliness
(Methods/ Procedures/Techniques) •Cost of material (part)
•Supplier selection procedure
•Supplier development method •Quality of materials (part)
•Purchasing procedure •Quick resource for any problem
•Purchased product control instruction concerned with material/part
Annex D
Process Audit Preparation “Turtle Diagram”
With What?
(Materials/ Equipment) With Who?
•Process equipment & machine (Competence/Skills/Training)
•Testing machine •APPQP team members who trained
•Material and skilled in applicable tool
•FMEA, DOE, QFD
Inputs
•Customer requirements e.g.
•Special characteristic
•Approval requisition Process Output
•Previous design projects DFMEA Establishing DFMEA which can prevent
•Field data & updating tensile strength failure
•Block diagram (7.1, 7.3)
•Preliminary process flow chart
•Material specification
How? With What Key Criteria?
(Methods/ Procedures/Techniques) (Measurement? Assessment)
•WI, Procedure far-forging •Fail rate
•Testing method/destructive testing (tensile) •PPM
•Poka yoke •Defect rate
•DOE
•Feasibility review method
•Part approved process
Annex E
Process Audit Preparation “Turtle Diagram”
With What?
(Materials/ Equipment)
•Safety equipment With Who?
•Transportation equipment (Competence/Skills/Training)
•Forklift •Trained personnel
•Truck/tailor •Qualified Driver
•Strapping machine
•Finished product
•Computerize system for product picking
Inputs Process Output
•Conforming product
•Customer specific requirement Delivery Control
•Delivery schedule delivery on time
•Delivery note/ invoice/documents
•Storage inventory level With What Key Criteria?
(Measurement? Assessment)
How? •On-time delivery performance
(Methods/ Procedures/Techniques) •Error rate
•Handling & delivery work instructor •Customer satisfaction score
•Labeling requirement •No customer complaint/claim
•Packaging requirement •Field return report
•On-time (EDI) system •Premier freight
•Training procedure
Annex F
Process Audit Preparation “Turtle Diagram”
Inputs With What? With Who?
•Customer requirement/SC (Materials/ Equipment) (Competence/Skills/Training)
•DOE •CAD/CAM •Product design skill personnel
•Block Diagram
•DFMEA
•Timing plan
•Regulatory requirement
•Functional & performance Process Output
requirement •Designed product
•Previous similar design Design (7.3) Meet design input
•Field data (input  output) •Design records e.g. drawing
•Competitor analysis
•Timing plan
•Preliminary process flow chart
•Design goal
With What Key Criteria?
How? (Measurement/Assessment)
•Design error rate
(Methods/ Procedures/Techniques) •Drawing compliance
•Design procedure
•APQP manual •Product life
•Math •Timeliness
Annex G
Process Audit Preparation “Turtle Diagram”
With What? With Who?
(Materials/Equipment) (Competence/Skills/Training)
•Overhead •Top management &
•Meeting room
management team
Inputs
•QMS requirement
•Business plan Process Output
•
•Process performance and analysis Management Review •Decision & action related to
Improvement process, QMS
•Field failure/impact (Target 5.6)
•Submit result •Product related customer
•Customer feedback satisfaction
•CA/PA status *recommendation for improvement
•Follow up action form previous
•Recommendation for improvement With What Key Criteria?
•Policy/object (Measurement/Assessment)
•Product conformities •Customer satisfaction
•Yearly plan How? •Improvement trend
•IQA Plan (Methods/ Procedures/
•Quality poling/objective framework Techniques) (of process/product)
•Meeting •Status of CAR/PAR
identification •VDO Conference •External nonconformities
•Verify report
Annex H
Process Audit Preparation “Turtle Diagram”
With What?
(Materials/Equipment) With Who?
•Internet
•Telephone (Competence/Skills/Training)
•Customer P/O •Trained staffs

Inputs
•Production capability
•Drawing Output
•Customer requirement •Getting Order
•Product requirement Process •Quotation issuing
•Regulatory requirement Contract Review
•Delivery requirement

With What Key Criteria?

How? (Measurement/Assessment)
(Methods/ Procedures/Techniques) •Sale volume
•Contact review procedure •Win in bidding
•WI No. of enquiring/order?
•APQP manual
•Feasibility review process
 Process Audit Preparation “Turtle Diagram”
With What? With Who?
(Materials/Equipment) (Competence/Skills/Training)
CAD/ CAM Program APP Team
Computer Product design engineer
Raw material Process design engineer
Strength test equipment

Inputs Output
Customer requirement Product conform to
ECN Design & Development strength test specification
Regulatory requirement
Previous similar design
Target for product quality
With What Key Criteria?
How? (Measurement/Assessment)
(Methods/ Procedures/Techniques) PPM
Strength test institution Scrap rate
APQP Manual Cpk
PPAP Procedure
FMEA Manual
Control Plan
 Process: Process design & development
Process owner: APQP Team
Process Input;
• Customer requirement
• ECN
• Regulatory requirement
• Previous similar design
• Target for product quality
 Process Activities
• Design Planning
• Design input review
• Design output review
• Design verification
• Design validation
• Design change control
• PPAP
 Support Activities
• Production; preparation of work instruction, train operator
• QC; inspection, MSA
• Maintenance; tools equipment making/ maintenance
• Sale; receiving of customer requirement & feedback
• Management; Management review
• Purchasing; purchasing of material
• HR; Training
• Engineering; packing standard etc.
 Interface/ Linage
Output
• Customer  Process flow diagram
• Supplier  Drawing
• HR  Special Characteristic
• Production  FMEA
• Maintenance  Control plan
 Working struction/ Job instruction
 Product for approval
 Measurement
• Time
• Correctness
• Ppk > 1.67

Reference Document/ Necessary Information

• APQP Procedure
• Customer requirement
• Regulatory requirement
• Functional requirement
• Company policy
 Material/ Equipment

• Computer (CAD/CAM)
• Sample part
• Jig/ Fixture
• Production machine (press, machining, etc.)
• Inspection tool
 Process Audit Preparation “Turtle Diagram”
With What? (ทำำด้วยอะไร)
(Materials/Equipment) With Who? (ทำำโดยใคร)
•Spare part (Competence/Skills/Training)
•Special purpose tools •Trained personnel (Service)
•Measuring equipment
Output (ผลลัพธ์)
•Service provided within
Inputs (ใช้ข้อมูลอะไร) Process Servicing Warranty period
•Warranty period document Repair •On-time correct service
•Customer specific Maintenance Conform to customer
requirement Service agreement (7.5.1.8) requirement

With What Key Criteria?

How? (ทำำอย่ำงไร) (วัดผลลัพธ์ดว้ ยเกณฑ์อะไร)
(Methods/ Procedures/Techniques) (Measurement/Assessment)
•Work instruction •Timeliness
•Service Manual •Error rate
•No returned job with some issues
& side effect
 1. Process Input (what do you need?)
• Warranty period document
• Customer specific requirements
• Service agreement and contract (จะเป็ น output ถ้ำเป็ น 7.2
audit, จะเป็ น input ถ้ำเป็ น 7.5 audit)
• Work instruction
• Trained personnel (skill, experience)
• Any special purposed tools or measuring equipment
 2. Process Activities
• Pre-inspection/ diagnosis
• Repairing Service
• Maintenance Service
• Testing
3. Support Process
• Contract Review
• Feasibility Review
• Training
• Production part/ spare part
• Tools & equipment maintenance
• Cost estimation
 4. Linkage/ Interface
• Customer
• Engineering
• Safety
• Financial
5. Process Output
• Service conformed to customer
6. Measurement (for process efficiency & effectiveness)
• Timeliness (Response time)
• Field return rate (Returned job)
• Error Rate
 7. Audit Planning (Activities for preparation)
• Identify Process
• Analyze Process
• Risk Analysis (input/output) and Audit Prioritize
• Follow up issue for previous audit
• Internal and External
• Audit plan (Sequence/ process step, timing, interview partners)
• Create complete checklist
 8. Fact verified during the audit
• Are those any organization service center?
• Any special purposed tools
• Who conducted diagnosis, repair, maintenance?
• What are services documents?
• Are spare parts appropriate provided?
• How is inspection/ Testing conducted
• Are measuring drive calibrated?
• How long does service taken?
 Analysis of Internal Audit Process
With Who? (ทำำโดยใคร)
With What? (ทำำด้วยอะไร) (Competence/Skills/Training)
(Materials/Equipment) •Independence
•Audit checklist •Trained
•Turtle diagram •Ski
•Export
Inputs (ใช้ข้อมูลอะไร)
•Objective
•Frequency Internal Audit Output (ผลลัพธ์)
•QMS requirement •Known QMS status of QMS
•QMS Status (QMS Audit)
•Customer Complaint
•Nonconformities
With What Key Criteria?
(วัดผลลัพธ์ดว้ ยเกณฑ์อะไร)
How? (ทำำอย่ำงไร) (Measurement/Assessment)
•Strength
(Methods/ Procedures/Techniques) •Weak point/ observation
•Work instruction
•Service Manual •Nonconformities
•Improvement items
•No. external nonconformities
 Supporting Process (Who help)
• Management Review
• Training

Interface/ Linkage
• Auditee
• Management of audit area
• Top Management

Process Input
• Know QMS status
• Improvement of QMS
 Necessary Information for Audit
• Procedure, Quality Manual
• Customer requirement
• Regulatory requirement

Audit Process
Process Owner : QMR
Lead auditor
Auditor
 Process Input
• Objective
• Frequency
• Status of QMS
• Customer Complaint
• Nonconformities
• QMS Requirement
Material & Equipment Activities
• Audit program planning
• Audit Plan/ schedule
• Auditor team assignment
• Document review
Process analysis
Checklist preparation

Audit schedule confirmation

Follow-up issues of prior audits

On-site audit

Conclusion of audit findings and audit report

Follow-up audit if necessary

Material Equipment
Form sheet for recording audit finding

Reference manual/ requirement