Traceability Check Sheet Company

Part Name, Number

I would like to confirm manufacturing record, change point record etc, check whether
Purpose of Audit: information is available without delay and confirm the certainty of that information by process
audi

Checklist
Check target No
Check Items
Level 1 Level 2

Check items) Do they have any rule to do inventory? and do they have check inventory and have inventory result?
1)There is no rule but give order verbally or by
OJT. 1) Periodic inventory : once a year.

2)They are checking finished product number 2) They are checking finished product and child
and QTY. parts,part number and QTY.
Manual of Department 1
3) Inventory record should be maintained.

Inventory

(Check items) Is there a rule to investigate the cause of inconsistency (mismatch) and countermeasures from the result of stocktaking? Are

1) There is no rule. - There is a rule only adjusting records and it is

Raw Material/Parts Inventory Management

2 implemented.
Result of Inventory 2) They are only adjusting records based on
inventory result. - They are reporting inventory result to concerning
parts & inventory management

department.

(Check point) Do they have any rule to record the parts supply information from store to each process of line? And do they have records?

Material in and out - There is no rule but they have recording - There is a rule to record the parts supply QTY.
Parts Supply(goods issue) 3 format.
Management - The history of loading and unloading parts to and
Records
- They are recording the finished product from the line is recorded.
despatch number and QTY.

(Query) Do they have any rule or contract to request to supplier to record the manufacturing informations like 4M control,in/out, inspectio

Purchasing Rule with

Manufacturing record suppliers, Purchasing 4 - Requesting to supplier in any condition. - Requesting documemt is available but contents
management (Not a official documents such as in E-mail) are not enough. (Request for despatch record,
Parts Quality Manual
production record, etc)

(Query) Do they have any rule to do the FIFO in store? And do they operate correctly?

FIFO(Parts loading and

Store Condition check 5
unloading)
onsite
 Checklist
Check target No
Check Items
Level 1 Level 2

- There is no rule but give order verbally or by - There is a display of FIFO like one point lession.
OJT. - They are operating as per instruction.
FIFO(Parts loading and Store Condition check 5
unloading) - Parts flow is fixed.
onsite
(No variationin some operators when hearing to
them.)
 Checklist
Check target No
Check Items
Level 1 Level 2

parts & inventory management

(Query) Do they have any rule to do the FIFO in process and between process? And do they operate correctly?

- There is no rule but give order verbally or by - There is a display of FIFO like one point lesson
OJT.
- Parts flow is easy to understand.
Process Check & 6 - Parts flow is fixed. (Parts should not go many locations)
FIFO (Process) (No variation in some operators when hearing (Clear parts separation)
Confirmation
to them.) (Model name plate is in parts box, etc)

Materials / parts / inventory management

(Query) Do they have any rule about approval of records? General rule or rule on each operation manual. And how are the records conditi

- There is no rule but recording formats have - There is rule about approval of records.
7 approval column and instruction given to
Approval of Records
operator.
- All records have to be approved.
Reliability of Records

Inspection record - All records have to be approved.

- All recording items have to filled up.
Dispatch record 4 M
change point record etc.
for each process etc.
Confirm actual record
(Query) Do they have any rule about storage of records? General rule or rule on each operation manual. And how are the records conditio

- There is no rule but filing method and storage - There is a rule for records retention and following
8 location instruction given to operator. it.
Records Retention
- Records maintained.(retained)
 Checklist
Check target No
Check Items
Level 1 Level 2

(Query) Do they have any rule for process change? And how are the records condition? It should store the files at one location.

- There is no rule, but they know YAMAHA - There is a rule for process change and following
requirement for process change. it.
Company Rule (What kind of process change have to report to
Responding to yamaha YAMAHA?)
request - Suppliers are reporting process change
Purchasing Rule with 9
(Mangement of Process information and will report.
suppliers, Purchasing
Change) Parts Quality Manual

Definition of Changing Point & the Validity of Judgment

Changing Point Mnagement

(Query) Do they have rule for spec change(customer requirment)? And how are the records condition? It should store the files at one loca

- There is no specific rule, but Their - There is a rule for spec change.
Management of Company Rule 10 understanding is to use part of other rule.
Specification Change - Each divisions are keeping spec change related
- Each divisions are keeping spec change data.
related data.

(Query) Do they have any rule for daily change point control? And how are the records condition?

- There is no rule but give order verbally or by - There is a rule to record daily change points like
OJT. machines and tool maintenance, man etc, and
actually follow the rule.
Internal rules - Daily change points like man,machines and
Management of change Production control /
point other than YAMAHA 11 tool maintenance, manning table, etc are
manufacturing record recording.
Requirment Production Records )
(Daily Control)
- There is a note(paper) to record daily change
points. (note, white board)
 Checklist
Check target No
Check Items
Level 1 Level 2

(Query) Do they have any rule for defective parts handling? And do they operate correctly?

- There is no rule but give order verbally or by - There is a rule for defective parts handling and

Defective Parts Handling & Scrap history

Defective Parts Handling & Defective Parts Handling 12 OJT. actually followed.
Rule, Record,onsite
Scrap disposal Rule
check - There is a record of defective parts.
(Can understand discard QTY and repaired
QTY)

(Query) Do they have any rule for defective parts segregation? And do they operate correctly?
Defective Parts Handling 13
Segregation of Defective
Rule, onsite confirmation - There is a box for defective parts. - Defective parts box is identified.
Parts
(Color, Warning, Shape, etc)
Changing Point Management

(Query) Do they have any rule to judge to issue deviation request? And do they operate correctly?

Deviation/concession
Internal rules / 14
processing record - They know what is deviation. - They know how to proceed deviation.

(Query) Do they have any rule about approval of records? General rule or rule on each operation manual. And how are the records conditi

- There is no rule but recording formats have - There is rule about approval of records.
15 approval column and instruction given to
Approval of Records
operator. - All records have to be approved.

- All records have to be approved. - All recording items have to filled up.
Reliability of Records

Process Change Record,

Defective Parts Handling (Query) Do they have any rule about storage of records? General rule or rule on each operation manual. And how are the records conditio
Record, Rework Record
*Check actual records
- There is no rule but filing method and storage - There is a rule for records retention and following
location instruction given to operato it.
- Records maintained.(retained)
16
Records Retention
 Checklist
Check target No
Check Items
Level 1 Level 2

Identification management (especially when there are two or more parts settings
(Query) Do they have any rule to judge to issue deviation request? And do they operate correctly?

- There is no rule but give order verbally or by - There is a rule for parts handling like packing
OJT. style, parts identification tag, etc.
Parts Handling 17 - One parts box use for only one part. - Parts identification tag has to be attached on
Parts Handling Condition, Parts (No mixup of parts in one box) each lot. (one tag for three parts box)
Identification Tag

Identification of Parts (Label, Parts)

(direction))

(Query) Do they have any rule for similar parts control? And do they operate correctly?

- There is no rule but give order verbally or by - There is a display of identification like one-point
OJT. lecture on machine or operation table, parts
shelves, etc, and parts supply workers are checking
- Operator or parts supply worker is checking it.
identification mark, or it can judge by
inspection.
Confirm with R &D / PE
Similar Parts Management department 18
On-site confirmation
 Audit Date 2015 / MM / DD

Auditor

Checklist Judge (1 or 2 or 3)
implement Detail of Judgment
Level 3 Acceptable Rule ation
status

o do inventory? and do they have check inventory and have inventory result?

1) Periodic inventory : once a half year.

2)They are checking parts and materials QTY in each process and
recorded

3) Record maintenance rule is there and followed.

4) Inventory result has to be approved by superiors and actually doing.

ate the cause of inconsistency (mismatch) and countermeasures from the result of stocktaking? Are you doing it again

- In case of inconsistency, it is supposed to identify the cause and carry

out improvement activities, and it is being implemented.

record the parts supply information from store to each process of line? And do they have records?

- Parts supply record is available with reasons like "Proto" "Parts Shortage",
etc.

act to request to supplier to record the manufacturing informations like 4M control,in/out, inspection data?

- There is an official request to supplier to keep despatch record and

production record, etc.
(Purchase Agreement, Quality Agreement, etc)

e FIFO in store? And do they operate correctly?

Checklist Judge (1 or 2 or 3)
implement Detail of Judgment
Level 3 Acceptable Rule
ation
status

- They have a rule of FIFO in detail.

- The layout of the parts storage is in consideration of first-in first-out.

(One-way parts, coloring labels, devising the shape of shelves, etc.)
 Checklist Judge (1 or 2 or 3)
implement Detail of Judgment
Level 3 Acceptable Rule
ation
status

e FIFO in process and between process? And do they operate correctly?

- They have a rule of FIFO in detail.

- Model name, parts number, lot number, QTY, etc have to display on parts
case.

- Parts storage areas are fixed between process to process.

*Is there any extra parts near by production line?

pproval of records? General rule or rule on each operation manual. And how are the records condition?

- Each records have to have fixed approver. (Post, Role, etc)

- All recording contents are necessary for the purpose of the record. (No
lack of information)

orage of records? General rule or rule on each operation manual. And how are the records condition?

- Strage limitation is fixed based of record importance.

- Strage location is clealy identfied. (Location control)

* Safety characteristic data must keep 10 years, and the others are 7, 5, 3,
1, 0.5 years keep as it record type according to Quality Manual.
 Checklist Judge (1 or 2 or 3)
implement Detail of Judgment
Level 3 Acceptable Rule
ation
status

ess change? And how are the records condition? It should store the files at one location.

- There is a rule to judge before issue process change request to YAMAHA.

(Check inspection data, etc)
- There is a rule for initial lot supply after YAMAHA approval for process
change request.
- There is a rule for initial lot tag has to attach on initial lot after process
change.
- One division is keeping all spec change related data.
- There is an official request to supplier to issue process change report.
(Purchase Agreement, Quality Agreement)

nge(customer requirment)? And how are the records condition? It should store the files at one location.

- There is a rule for spec change and QC Process Chart and Operation
Manual, Inspection Standard, etc will be maintained by following the rule,
and actually followed.

- One division is keeping all spec change related data.

change point control? And how are the records condition?

()
- There is a rule to record daily change points like machines and jigs
maintenance, manning table, etc, and correctly followed.
(Can trace the defective lot from the record)
(Can minimize the defective range by the record)
 Checklist Judge (1 or 2 or 3)
implement Detail of Judgment
Level 3 Acceptable Rule
ation
status

ctive parts handling? And do they operate correctly?

- There is a record of defective parts.

(Can understand discard QTY and repaired QTY per lot)

- There is a record of repaired parts.

ctive parts segregation? And do they operate correctly?

- There is a company rule for identification of defective parts box and

actually followed.

to issue deviation request? And do they operate correctly?

- There is a rule based on YAMAHA deviation standard and actually

followed.

pproval of records? General rule or rule on each operation manual. And how are the records condition?

- Each records have to have fixed approver. (Post, Role, etc)

- All recording contents are necessary for the purpose of the record. (No
lack of information)

orage of records? General rule or rule on each operation manual. And how are the records condition?

- Strage limitation is fixed based of record importance.

- Strage location is clealy identfied. (Location control)

* Safety characteristic data must keep 10 years, and the others are 7, 5, 3,
1, 0.5 years keep as it record type according to Quality Manual.
 Checklist Judge (1 or 2 or 3)
implement Detail of Judgment
Level 3 Acceptable Rule
ation
status

to issue deviation request? And do they operate correctly?

- One parts identification tag has to attached on each parts box.

- Necessary informations have to mention on the tag.

(Parts Number, QTY, Lot No., Production Date, etc)

ar parts control? And do they operate correctly?

- There is a rule for similar parts control. (No need to make individual rule,
It is written on production preparation rule that who and when make
similar parts control display, documents.

- There is a display of similar parts for the attention. (Photo or actual parts
display, etc)

- Identification check process has to be on process chart and actually

followed.

- There is an inspection process afterforging and followed.