This document provides an overview of process auditing in the automobile industry. It highlights the importance of having: 1) A holistic view of the overall organization structure and understanding processes, inputs, and outputs. 2) Using tools like SIPOC, COPs, 6M1E, 5W2H, and 5Whys to analyze and simplify individual process steps and define the audit scope. 3) Executing an on-site audit by reviewing past reports, data, value stream maps, process flows, and product documentation to understand performance and identify bottlenecks.

1. Process Audit in Automobile Industry
Prepared by Bill Yan
May 12, 2015
1. You are God to Own your business(Ownership)
2. Know what you know, and know what you don't know (SWOT)
Highlight 2 mindsets for audit:

2. Analyse Typical Organization Structure
 Holistic view全局观点
 B process一个过程
 “the what” “什么”
A Process
 A procedure一个程序
 “the how” “如何”
A process Step(PS)
Owner – General Manager/ Plant Manager
负责人-总经理/厂长
 “measure business performance”
finance, customer, innovation--KPI
测量业绩、财务、顾客、创新
 measure efficiency/effectiveness
basis for Activity Based Costing
根据成本核算测量活动的效率/有效性基础
Owner– Process Owner ( Project Leader)
 “ the Why”
A System
 Human Factors— Delivery Personal
Quality Job, Beat your plan Everyday
Owner- Operators
--- To define the process for audit scope

3. 2. More Data & Detailed ! 3.Think different( SIPOC or COPs? )
1. y=f(x1, x2, x3…)
Manage process factor
Analyze Process

4. Process Definition, Structure and Interfaces(WBS , DMAIC, and Audit Scope)
Analyze and predigest the process to be more simple process step (PS) and define audit scope

5. Process breakdown and analysis: 6M1E, 5W2H, 5Whys
PS output( COP)
Input
Man
Machine
MSA( SPC)
Money (optimize cost)
Materials
Method( FMEA)
Environment
VDA6.3 provide the Questionnaire to every M , It is very helpful to process audit and
reduce process risk.
Base on Value, Data, Factual approach to detailed manage process factor
Why
What
Who
Where
When
How long
How much
Refer to Quality management 8 principles + AIAG core 5 tools to manage the PS
+ 5whys

6. Execute Process Audit(Highlight)– before on-site audit
1. Check last audit report, management review report and CAPA(8D) ---To
know overall management level and process capacity expectation
2. Aftersales service data and customer satisfaction performance review
( How to analyze these data and feedback them to Marketing, R&D and
Process owner by procedure?---VOC for DFMEA, an typical Process for
customer satisfaction/CRM)
3. Analyze Value Stream Map(VSM) to know process bottleneck and CIP
4. Analyze Process flow chart and Process control plan(analyze WBS for PS)
5. Typical 2 or 3 products APQP and PPAP review
6. Respect, Time, Patience , Fact, Communication and Result
7. Balance listening and question during audit
8. Balance conflicted process capacity, resource, priority, and interaction of
related processes to optimize system

7. Measurable Assessment Process– QAKE

8. Process Specific Audit Questionnaire/Detailed Audit Plan-- On site Audit by track

9. Q&A
Thanks for your time , Please feel free to contact me if you have any query.