INTERNAL QUALITY AUDIT Model : Date :

BASED ON ISUZU RATING CRITERIA (B) AUDIT Part Number :

GENERAL SUB
5 4 3 2 1 TOTAL COMMENT
CATEGORIES CATEGORIES
1.QA STANDARDS 1) Preparation of standards

2.CALIBRATION 2) Accuracy control of instruments and measuring tools

SYSTEM
3) Maintenance and storage of instruments and measuring tools

3.FACILITY CONTROL 4) Productive maintenance (plan and practice)

and routine check of machines and equipments

5) Maintenance and storage of dies, jigs, cutting tools and

hand tools
4.PROCESS CONTROL 6) Adherence to standards

7) Monitoring process quality

8) Control of process change, initial product, etc

5.PARTS/PRODUCTS 9) identification and storage of defects and reworks

CONTROL
10) Product handling operation, storage, handling, packaging
and First-in and First-out

6 .INSPECTION 11) Inspecting practice

12) Record, maintenance and feedback of inspection results

7 .DEFECTS HANDLING 13) Procedures and forms

14) Communication and analysis

15) Cause analysis and recurrence prevention

 GENERAL SUB
5 4 3 2 1 TOTAL COMMENT
CATEGORIES CATEGORIES
8.TRAINING 16) Quality / skill tuning and descipline

9.WORKPLACE 17) Disposition, neeteness, cleaning, hygiene and discipline

ENVIRONMENT (5S)
10.PREPARATION FOR 18) Progress control
PRODUCTION
19) Recurrence prevention for experienced defects

20) Supplier control

21) Delivery control (Submission to customer)

11.IMPROVEMENT 22) Quality assurance system

23) Process

12.CRITICAL PARTS 24) Critical parts control procedures,identification in process etc.

CONTROL
25) Assurance of critical and safety characteristics

26) Lot control

Total Points : ________ Points

PASS Evaluation Grade
EVALUATION Approved Checked Evaluate Evaluating Method
RESULT Must items should Item 1 PASS FAIL Evaluate from checked and excepted sub categories
FAIL be achieved Item 4 PASS FAIL Total Points x 100%
Evaluation Results(%) =
4 points or more Item 12 PASS FAIL 130-(5xnumber of accepted sub categories)

Grade Level Judgement

≥ 90 = A Point 1 Not Acceptable / Fail
≥ 80 = B Point 2 Poor
≥ 60 = C Point 3 Satisfactory / Fail
< 60 = D Point 4 Good
Point 5 Excellent
 GENERAL SUB CHECK MUST WHAT TO
POINTS
CATEGORIES CATEGORIES ITEMS ITEMS CHECK
1.QA 1) Preparation of standards 1. Are lists of standards poesesed at every shop? Is the document hierarchy to be understood? (*) DOCUMENT
STANDARDS Are process control condition table as well as checksheet prepared?
2. Are contents of related standards consistent? (*) DOCUMENT

3. At processes, are necessary standards prepared, refered easily, free of fade, dirt and damage and legible SHOP

4. Are necessary amandments implemented as defined? Are objects to be controlled defined? (*) SHOP
Is inventory control book maintained?
2.CALIBRATION 2) Accuracy control of instruments 5. Are control rules (standards and manuals) established? Are objects to be controlled defined? (*) BOTH
SYSTEM and measuring tools Is inventory control book maintained?
6. Is periodical accuracy calibration conducted as defined with the annual plan? (*) SHOP

7. Isaccuracy calibration conducted as defined in calibration standards? Are the-results recorded SHOP
with numeral values? Are the records easy to show trends or fluctuations?
8. Are the instruments objective for control checked daily? Are failures detected and corrected ? (*) SHOP

9. Are calibration status displayed and within period validity? SHOP

3) Maintenance and storage of 10. At processes, are the necccesary instruments defined with quality standards allocated? (*) SHOP
instruments and measuring tools
11. Is handling suitable? Are they placed adequately and free from rust, dust, oil or water? SHOP
Are they not placed together with cutting tools, jigs and hand tools?
 GENERAL SUB CHECK MUST WHAT TO
POINTS
CATEGORIES CATEGORIES ITEMS ITEMS CHECK
3.FACILITY 4) Productive maintenance (plan and 12. Are facility control procedures/rules established? (Are control standard defined?) (*) DOCUMENT
CONTROL practice), and routine check of
machines and equipments 13. Are annual plan of productive maintenance prepared? Are check records maintained ? (*) DOCUMENT

14. Are dairy checks defined ? Are the checks conducted ahd recorded as defined ? SHOP

15. Are foolproof equipments and inspection dummies checked In accordance with rules? SHOP

16. Are the defected nonconformances of facilities recorded and corrected adequately? SHOP

5) Maintenance and storage of dies,
jigs, cutting tools and hand tools
4.PROCESS 6) Adherence to standards
CONTROL
17. Are dies, jigs, cutting tools and hand tools maintained as specified and held in allocated places? (*) SHOP
( Location, prevention against rust, dust, water etc )
18. Are there preventive provision such as identifying marking, against improper use of dies, SHOP
jigs/cutting tools, and hand tools? Are used cutting tools distinguished from new tools?
19. Are checking/replacement Intervals defined for wear-out, of dies, jigs and fixtures? SHOP
Are checkings/ replacements conducted as defined ?
20. Do operation follow applicable standards? (*) SHOP
21. Are specified measuring tools, jig, hand tools, sample products and consumable materials used? SHOP

22. Are the rules apllying to operation interruption followed? SHOP

23. Is quality-in-process verified as defined ? (*) SHOP

7) Monitoring process quality 24. Are adequate tools such as check sheets, and control charts prepared for monitoring processes? (*) DOCUMENT

25. Are initial products verified end recorded after tooling changes and cutting tool replacement? (*) SHOP

26. Are quality performance of newly assigned workers-verified end recorded by supervision? (*) SHOP

27. Are initial, intermediate, and final products checked? (*) SHOP

28. Are mistake-proofs prepared as necessary ? SHOP

 GENERAL SUB CHECK MUST WHAT TO
POINTS
CATEGORIES CATEGORIES ITEMS ITEMS CHECK
4.PROCESS 8) Control of process change, initial 29. Are the process change and initial product processed as defined? (*) DOCUMENT
CONTROL product etc
30. Are criteria for reporting process change to customer specified? DOCUMENT

31. Is quality evaluation / verification conducted after process change and its initial product? (*) DOCUMENT

5.PARTS / 9) identification and storage of 32. Are defects or reworks handled as treatment standard: such as location/color of containers (*) SHOP
PRODUCTS defects and reworks or product identification?
CONTROL 33. Are cause analysis, corrective action and recurrence prevention conducted and recorded ? (*) SHOP

10) Product handling operation,
storage, handling, packaging and
First-in and first-out
34. Are parts selves and container identified with part no. and part name? (*) SHOP
Are the containers allocated at specified places? Are the containers free of dirt and damage?
35. Are parts and products handled not roughly? Are/muitiple kinds of parts not contained at one container? (*) SHOP
Are the containers fabricated as to prevent dust and rust?
36. Is a procedure to handle dropped items and suspect items defined? Are operation implemented as defined? SHOP

37. Are lot numbers and production numbers allotted to toe specified parts and recorded? (*) SHOP

38. Are amounts/inventory of parts adequate and handled in first-in/first-out ? (*) SHOP

39. Is shipment packaging as same as approved by customer? SHOP

6 .INSPECTION 11) Inspecting practice 40. Do the inspection procedures consist with inspection standards approved by customer in sampling frequency, (*) DOCUMENT
criteria, measurement instrument etc ? Are inspection performed as specified ?
41. Are measurement instruments and sample parts are used adequately ? (*) SHOP

42. Are Inspection premises suitable? SHOP

43 . Are inspection personnels qualified and trained enough ? SHOP

 GENERAL SUB CHECK MUST WHAT TO
POINTS
CATEGORIES CATEGORIES ITEMS ITEMS CHECK
6 .INSPECTION 12) Record, maintenance and 44. Are inspection results recorded as specified? Are record retention periods defined and followed as specified? (*) SHOP
feedback of inspection results
45. Are nonconformance product handling and information transmission/recording implemented as specified? (*) SHOP
Are cause analysis, corrective action and recurrence prevention conducted as specified?
7 .DEFECTS 13) Procedures and documents 46. Is defects defined? Are defects handling procedures established? (*) DOCUMENT
HANDLING
47. Is the product problem report form generated as to trace P-D-C-A? (*) DOCUMENT
Is a column for effectiveness provided with?
48. Are there rules of who should make decision on defects handling and action, to take? SHOP

14) Communication and analysis 49. Is a system, that an information of occurred defect surely reported to the process of the defect and (*) SHOP
the responsible personnel, established and implemented as specified?
50. Are temporary action taken immidiately for the defects? (*) SHOP

51. Is information of defect notified to all operators of the process (morning meeting, display, etc)? SHOP

52. Is a defect analyzed in a timery way and is the information transmitted to related sevtions? SHOP

15) Cause analysis and recurrence 53. Are cause analysis and corrective actions (for customer and in-house defects ) implemented and recorded? (*) DOCUMENT
prevention Are the reports submitted to customer in due dates?
54. Are the effectiveness of the corrective actions surely verified? SHOP

55. Is horizontal deployment performed? Are standards reviewed for recurrence prevention as necessary? (*) BOTH

56. Are the records filed needy and avalaible-anytime? DOCUMENT

8.TRAINING 16) Quality / skill tuning and 57. Are effective training curriculums of individual shop and level for both of operators and staffs prepared? (*) DOCUMENT
descipline Are training plans established and implemented as planned ?
58. Are both of operators and staff sufficiently trained for responsible processes ? (*) DOCUMENT

59. Are effects and effectiveness of training evaluated at every shop ? SHOP
 GENERAL SUB CHECK MUST WHAT TO
POINTS
CATEGORIES CATEGORIES ITEMS ITEMS CHECK
9.WORKPLACE 17) Disposition, neeteness, cleaning, 60. Disposition: Are things unnecessary and useless in present job, completely removed? (*) SHOP
ENVIRONMENT hygiene and discipline Neetness; Does each of the items have-own place and rested there?
(5S) 61. Cleaning: Are shops cleaned thoroughly and maintained ? (*) SHOP
Hygiene: Is working environment comfortable as no contaminants are left?
62. Discipline: Are shops rules observed? (*) SHOP

10. 18) Progress control 63. Is any system prepared for overall progress control? (*) DOCUMENT
PREPARATION Is operation conducted according to the system?
FOR 64. Is there enough communication in taking over from the engineering sections to production shops DOCUMENT
PRODUCTION (design review, etc…) ?
65. Are evaluations conducted sufficiently for dies, equipments, parts, standards, actual operations etc? (*) DOCUMENT
Are detected problems followed and solved ?
66. Are responsibility and authority.of general evaluation end judgment at prediction launching and (*) DOCUMENT
early production, containment clearly documented and conducted as defined?
19) Recurrence prevention for 67. Are previously experienced defecte accumulated as materials ? Is there a system to utilise the experiences ? DOCUMENT
experienced defects (e.g. FMEA, DR, QA-Matrix etc)
68. Are the problems, occurring in the pilot production solved? (*) DOCUMENT
Are the applicable standards reviewed to prevent recurrence of such problem?
20) Suppliers control 69. Are the agreements on quality with suppliers conducted as specified? DOCUMENT

70. Are the products and processes evaluated sufficiently? (*) DOCUMENT

21) Delivery control (Submissions 71. Is a system that customer's approval for Inspection stahdards shall be received prior initial delivery, (*) DOCUMENT
customer) or the initial delivery identification sheet, the test results, and layout inspection data for all characteristics
described at drawing shall be attached at initial delivery established ?
Are the items and documents required by customer submitted at specified due date ?
 GENERAL SUB CHECK MUST WHAT TO
POINTS
CATEGORIES CATEGORIES ITEMS ITEMS CHECK
11. 22) Quality assurance system 72. When any quality defect occurs, and when any system defect is detected, is quality system reviewed (*) DOCUMENT
IMPROVEMENT as appropriate ?
73. Is the system review approved by corresponding responsibility and input to management review ? (*) DOCUMENT

23) Process 74. For bottle neck processes, including machines and/or equipments/are relevant improvement (*) BOTH
targets established and promoted ?
75. Are the improvement progress and results confirmed by the top management ? (*) DOCUMENT

12.CRITICAL 1. Is a control procedure established ? (*) DOCUMENT

PARTS CONTROL
2. Are the sign 'CRITICAL" displayed cm the processes and facilities which handle critical and safety parts? (*) SHOP
A) Critical parts control procedures,
Are the critical characteristics inspection processes provided with the sign "CRITICAL"?
identification in process, operator
Are critical parts provided with identification tags?
3. Are there registration procedure for personnels in charge? Are multiple operators registered? SHOP
Are sufficient trainings regarding critical and safety parts conducted ?
4. Is a system to assure 100% conformance established? (*) SHOP

5. Do the critical and safety characteristics have sufficient process capability ? (*) DOCUMENT
B) Assurance of critical and safety
Are the process control parameters recorded ?
characteristics
6. Is the critical defect information fed back to toe responsible section ? (*) DOCUMENT
Is the defect information utilized to deployed to related parts horizontally ?
Are the previously produced parts checked in quality reteroactively and recorded ?