Process audits are a essential quality tool for you to evaluate your supplier’s manufacturing production to ensure that the materials and processes used can fulfill 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:
- Technical Documentation – Checks the supplier has the correct documentation for the product to be manufactured
- Receiving Materials Management – Assess the supplier’s methods for managing sub-suppliers and 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
From our audits, we can identify the required corrective actions for performance improvements and production risks mitigation.
Layered Process Audits
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 the audit and 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.