Process Audits

Process Audits at AMREP

Process audits are an essential quality tool for you to evaluate your supplier’s manufacturing production to ensure that the materials and processes used can fulfil your product standards and technical requirements. Our objective is to eliminate potential quality issues and production problems.

AMREP’s supplier process audits will look at the supplier’s manufacturing processes to verify:

Most Suppliers are certified to industry quality management and regulatory standards like the ISO 9000 and the IATF 16949. These certifications are easily achievable from third party certification bodies. They are positive sounding marketing tools. They are by no means a guarantee that the supplier’s QMS is effective or actually applied.

A certification only establishes that a supplier’s quality management system met certain conditions at a certain period of time. It is not a statement of how the supplier will address the specific quality requirements of your product.

Technical Documentation – Checks the supplier has the correct documentation for the product to be manufactured.
Receiving Materials Management – Assess supplier’s methods for managing sub-suppliers incoming material controls.
Design Record – Includes key characteristics identification
Design Failure Mode and Effects Analysis (FMEA) – Quantifies risks or potential failures
Process FMEA – Quantifies risks or failures due to the processes used.
Control Plan – Lists the SPC and other controls needed to lessen potential failures
Standard Operating Procedures – Describes work that flows across functions
Work Instructions – Describes work done at a work station

Layered Process Audits at AMREP

For companies with advanced quality management requirements, AMREP offers Layered Process Audits (LPA) for you to verify your supplier’s process conformance on an on-going basis. We work with your supplier’s management team to institute a LPA system that uses a sustained cycle of evaluating, monitoring, and corrective actions to inculcate a ‘whole of organisation’ culture of quality and continuous improvement.

In developing a LPA program we focus on:

Stakeholder identification and training – identifying persons who should be conducting audit, training them in auditing processes
Process definition – identifying the key processes that need ongoing auditing and defining audit parameters
Corrective actions – analysis, development, and implementation
Follow-up – Ensure that continuous improvement actions are followed up on

Customers who use our LPA programs find that they have lower direct material, rework, inspection, and production costs. They see decreased supplier defect rates due to a shift towards a proactive and preventative quality risk management approach.

Say Hello to us