What does a manufacturing process involve?
A manufacturing process comprises a set of principles, protocols and steps that have been established to track the manufacturing process of using raw materials from the beginning to the final product. Manufacturing processes may vary, depending mainly on the type and size of the operation and organizational preferences.
This article deals with the following topics:
1. What are process audit checklists?
2. Frequent errors in the manufacturing process and their avoidance
3. A mobile app for a process audit check list according to a catalogue of questions
What is a process audit checklist in production ?
Manufacturing plant managers and compliance officers use a process audit check list to ensure that the plant meets organizational and legal standards. A typical internal audit includes a site visit to verify that employees follow best practices and prescribed protocols. This is necessary to ensure consistent, high-quality production.
Frequent manufacturing errors in the production process and their prevention
A production plant fulfils many interdependent processes that must interact efficiently. An inefficient process or a malfunction, even in only one area, has negative consequences for the entire production line. Some of the most common manufacturing errors and some tips on how to avoid them are described below:
- No regular inspection plan
The management should regularly check the manufacturing process and production hall using a process audit with a suitable list of questions. This will ensure that everything runs as planned and agreed. Also done to keep an eye on the availability of the necessary equipment, facilities, the PPE and everything else that workers need to carry out their work properly. An effective inspection application helps compliance officers and plant managers evaluate performance, facilities and task assignments.
- Inappropriate documentation of data, defects and malfunctions
Data acquisition is an unpopular and superficially treated topic in many companies if only the expected production targets are in focus. However, efficient data documentation is necessary to see in which areas processes work successfully and where improvements need to be made. In order to contain problems at an early stage, incidents such as identified defects, malfunctions and non-compliance with regulations must be properly documented. Only then can long-term solutions be formulated and finally implemented.
- Choosing the wrong company for outsourcing
Outsourcing some or all of the production is a popular means of reducing costs in several profitable industries, including the technology and pharmaceutical industries. However, to successfully outsource, top management must select, compare and review various potential producers. This is the only way to assess whether their facilities, skills and experience are a good match for their own product.
- Lack of responsibility
A clear structure of responsibilities improves the entire manufacturing process. Employees are forced to be more careful, as non-compliance with regulations can be traced back to them. It is, therefore, necessary to designate personnel responsible for certain equipment, production stages and services. Besides, a single point of contact for various aspects of manufacturing facilitates and speeds up the exchange of information and communication. A fair system of responsibilities reduces the likelihood of human error and failure, which has a negative impact on the entire production process.
Mobile app for process audit checklists with a catalogue of questions
Collecting, organizing and documenting paper audits A paper-based process audit checklist consumes time, energy and space for collecting, documenting and organizing. These three resources can be better utilized by downloading Lumiform, the powerful, mobile inspection application. Lumiform, with its many features and user-friendly interface, has revolutionized safety and quality in a wide range of industries. With the Lumiform app, the following tasks can be better accomplished:
- Use a ready-made process audit check list for checking production processes and adapt it to your own needs.
- The collected data is automatically synchronized with the cloud as soon as a connection to the Internet is re-established.
- Take photos of defects, malfunctions and non-compliance with regulations and document them for better transparency.
- Identify problems and assign corrective actions to responsible employees to resolve the problem immediately. The time, date and priority level of the tasks can be defined.
- Automatically generate a report after completion of process audits checklists and immediately pass it on to management and staff.
- Track inspection frequency and performance using data analysis and gain actionable insights to improve operations.