Shop floor audits
Set up a system of regular shop floor audits, carried out in shop floor-office pairs, to spot deviations from standards before they cost a breakdown, an accident or a non-conformity.
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This course is aimed at team leaders, shop floor managers, continuous improvement facilitators and quality, maintenance or HSE managers who notice that the rules defined on the shop floor are applied less and less over time, without anyone realising it before the incident.
By the end, you will know how to write an audit checklist made up of YES / NO / N/A questions, calculate and display a score, set an audit frequency suited to the criticality of each area, form auditor pairs mixing shop floor and support functions, and keep the system alive beyond the first three months. The course also distinguishes the shop floor audit from what it is not: an informal shop floor walk (gemba walk), a product quality inspection or a certification audit.
What you will be able to do
- Explain why an uncontrolled standard drifts, and name three "well-meaning" motivations that lead people to deviate from it.
- Write an audit checklist of 8 to 15 closed questions, worded so that YES is the correct answer, with proper use of N/A.
- Calculate an audit score as a percentage and display it on the visual management board of the audited area.
- Choose an audit frequency according to the criticality and variability of the process, and know which checks do not fall within the scope of the shop floor audit.
- Form rotating shop floor-office auditor pairs and define who drives the system.
- Handle an observed deviation: record it, alert the person in charge, follow up the action, without the auditor intervening themselves.
The path
- Without control, the standard drifts 4 min
- Writing the question checklist 4 min
- Calculating and displaying the score 3 min
- Set the rhythm and the schedule 3 min
- Form the auditor pairs 4 min
- Keeping the system alive after the launch 4 min
Prerequisites
No Lean prerequisites. You must have at least one written standard on the shop floor (safety instruction, process parameter, preventive maintenance plan or 5S standard): the audit checks a standard, it does not replace it.
The closing quiz
The topic ends with a 7-question quiz, and a certificate is issued on success.