what is an Online production audit
An Online Production Audit is a remote assessment of manufacturing
processes and quality control measures, typically conducted using digital technologies.
An Online Production Audit is a virtual inspection of a manufacturing facility's production processes, quality control systems, and overall operations.
It's performed
remotely using various digital tools and technologies, allowing auditors to assess production activities without being physically present at the facility.
Key aspects include, live video streaming of production lines, real-time communication with on-site personnel, review of digital documentation and records, use of IoT
devices for real-time data collection, virtual facility tours, remote interviews with key staff members and analysis of production data and quality metrics.
This method of auditing has gained prominence, especially in situations where travel is restricted or to reduce costs and time associated with on-site visits.
It allows for timely assessments while maintaining social distancing protocols when necessary.
Key elements of Online production audit
Online Production Audits represent an evolving approach to quality
assurance and compliance verification, offering new opportunities for efficient and frequent assessments while also presenting unique challenges that require careful
management and continuous improvement of methodologies.
Its purpose is to access manufacturing processes remotely, verify quality control measures, evaluate compliance with standards and regulations, monitor production
efficiency and output.
The technologies used are high-definition video cameras and streaming software, secure video conferencing platforms, cloud-based document sharing systems, Internet of
Things (IoT) sensors and devices, Augmented Reality (AR) for guided inspections and Artificial Intelligence for data analysis.
The process of Online Production Audits can be summarize in the following steps:
a. Pre-audit preparation:
- Scheduling and coordination with the facility
- Providing a list of required documents
- Setting up necessary technology
b. Opening meeting:
- Introduction and agenda setting via video conference
- Explanation of the audit process to facility management
c. Virtual facility tour:
- Guided video walkthrough of the production areas
- Focus on key production stages and quality control points
d. Document review:
- Examination of digital quality records, procedures, and certifications
- Review of production data and performance metrics
e. Remote interviews:
- Video calls with key personnel (e.g., quality managers, production supervisors)
- Discussion of processes, challenges, and improvements
f. Live production observation:
- Real-time video streaming of active production lines
- Remote guidance for close-up inspections of specific areas
g. Data analysis:
- Review of real-time and historical production data
- Assessment of quality control statistics
h. Closing meeting:
- Summary of findings and initial recommendations
- Discussion of next steps and action items
Benefits of using Online production audit
Key Areas of focus of online production audit are as follows:
a. Production Capacity Assessment:
- Machinery and equipment evaluation
- Production line efficiency
- Quality control checkpoints
- Material handling and storage
- Worker safety and PPE compliance
- Equipment maintenance and calibration
- Environmental controls
- Product traceability systems
b. Advantages:
- Cost-effective compared to on-site audits
- Reduces travel time and associated risks
- Allows for more frequent assessments
- Enables quick response to urgent issues
- Provides flexibility in scheduling
c. Challenges:
- Limited physical inspection capabilities
- Potential for technology failures or connectivity issues
- Difficulty in assessing workplace culture and employee interactions
- Possible resistance from facilities unfamiliar with technology
d. Best Practices:
- Thorough pre-audit preparation and technology testing
- Clear communication of expectations and processes
- Use of multiple camera angles and high-quality audio
- Combination with periodic on-site audits for comprehensive assessment
- Secure data transmission and storage protocols
e. Types of Online Production Audits:
- Initial qualification audits
- Routine compliance checks
- Follow-up audits for corrective actions
- Crisis response audits (e.g., during pandemics)
f. Reporting and Follow-up:
- Detailed audit reports with screenshots and video clips
- Clear action plans for identified issues
- Virtual debriefing sessions with facility management
- Scheduled follow-up checks on corrective actions
g. Integration with Other Systems:
- Connection to ERP and quality management systems
- Integration with supplier management platforms
- Linkage to customer compliance portals
h. Training and Competency:
- Special training for auditors in remote assessment techniques
- Development of virtual communication skills
- Familiarity with relevant technologies and platforms
g. Limitations and Considerations:
- May not be suitable for all types of audits (e.g., detailed machinery inspections)
- Potential for staged or selective presentation of facility conditions
- Need for contingency plans in case of technical difficulties.