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Audit Tips

Previous findings – In preparation for an audit, make sure you have included assessing to assure previous audit findings have been abated.

Procedure

Process Technique Approval – All procedures and process techniques or instruction sheets used for processing and/or evaluation of components must be approved by a level 3 in most cases. It is important to remember that if you are inspecting parts for an aerospace prime that requires them to approve the level 3, that level 3 must approve the procedure and other instructional documents.  If you had a customer approved level 3 and that level 3 no longer works for you, you will have to obtain another approved level 3 and you will likely have to have that person re-approve the previously approved documents.  You may have be able to be creative in how you do this with the least amount of administrative work, but be sure the approving customer agrees in writing, your method of approval.

Records – Make sure you now record somewhere what specifications were used for the inspection and the revisions of the specification used.  This can be in a job log or on a final test report.  It is important for a prime customer to be able to trace an inspection to the specific acceptance criteria use at the time a component was inspected. Process

Trainees – When you are training someone in the process and they have a trainee status, make sure you are documenting all training they receive and that they do not independently perform any operations, unsupervised, unless detailed appropriate documents are in place and approved by the level 3. Process Control

Process Control Failures – Make sure you procedurally cover what to do if a process control check fails, including notification of customer if parts cannot be re-inspected or have been shipped before the failure was found.  If you record the check as a failure, make adjustments and bring the check into compliance with requirements, make sure you re-record the accepted check.

Procurement

Purchasing and P.O.'s - It is vital to flow down all required technical information on a P.O. to the subcontractor who is providing you with a product or service. Keep in mind that anything required to meet a specification should have that specification referenced either on the P.O. or a document containing the specification requirements should be referenced on the P.O.

Examples -
  • When purchasing Master Film Step Wedges, state on the P.O. that the item "must be calibrated NIST traceable."
  • For having parts penetrant tested by a testing lab, give adequate identification (P/N, Drawing Revisions, etc.) state what specifications and revisions the part must be tested and certified to meet.
  • For calibrations, state the standard to be used, accuracy requirements, range to be checked and the number of points over the range to be checked, frequency, and what calibration system requirements must be met (e.g. ANSI/NCSL Z540–1 or ISO 10012–1). Note: If you have a subcontractor that calibrates a number of items, this technical information could be documented in a spreadsheet and given identification for procedure and other tracability (i.e. and document title or form number) and this document could be referenced on a P.O. and sent to the calibration source. As the document is revised because of change in requirements or items to calibrate, you can just send the revised document to your calibration source.

 

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