What is a Process Audit?
A process audit is a systematic review that assesses compliance with predefined standards. In a manufacturing environment, this means verifying that machine settings align with production requirements, ensuring consistent output and efficiency.
A well-executed process audit identifies critical process parameters that directly impact quality and performance. Given the complexity of modern manufacturing, with potentially thousands of settings influencing production, focusing on the most impactful variables is essential.
How to Build an Effective Process Audit
The foundation of an effective process audit begins with understanding:
- Product specifications – What are the required quality and performance standards?
- Equipment performance characteristics – What are the optimal machine settings for production?
- Historical process data – What past challenges have led to adjustments in process settings?
Process audits should be continuously refined. Every production issue—whether a defect, inefficiency, or downtime event—presents an opportunity to enhance the audit by identifying new parameters to monitor.
Can You Audit Too Many Factors?
Not necessarily, but the key challenge is efficiency. Conducting frequent and extensive manual checks can be time-consuming. The solution may lie in the combining manual with smart and automated data collection.
Automation interfaces can provide “free data”—critical process insights gathered without manual effort. Leveraging automated systems for data collection allows manufacturers to focus on high-value monitoring activities while ensuring comprehensive oversight.
Timing Your Process Audits for Maximum Impact
The ideal audit frequency depends on process variability. The goal is to check parameters just before they cause failures. To achieve this, manufacturers need data-driven sampling strategies:
- Use historical process data to identify patterns and determine when variations typically occur.
- Establish variable sampling frequencies – Some settings may need hourly checks, while others require only shift-based or daily verification.
- Adjust frequencies over time based on analysis and performance insights.
Creating Process Auditing & Monitoring Applications with Quality Window
Quality Window provides multiple solutions for building and optimizing process audits:
Custom Process Auditing Applications
- Use the Admin to create process monitoring applications by defining variables and setting performance limits.
- Easily revise applications without losing historical data.
- Integrate device interfaces (e.g., scales, sensors, PLC systems) to reduce manual data entry and improve accuracy.
Automated Data Collection
- QWScheduler Utility enables automated data capture based on time or event triggers, ensuring timely and accurate process insights.
- Reduce manual entry and improve efficiency by automating routine audits. (Learn more about automating data collection).
Integrating External Data Sources
- Excel to QW6 (XLtoQW) – Convert structured Excel worksheets into QW Applications with specs and targets for instant analysis. (Watch tutorial ).
- SQL Data Integration (QW6 SQLWizard) – Extract and analyze process data from SQL databases directly in QW6. (Watch demo).
Start Quickly, Improve Continuously
QW6 is designed for adaptability—start with essential audits and expand as you gain insights. With a combination of manual, automated, and integrated data collection tools, manufacturers can achieve continuous process improvement while reducing compliance risks.
Ready to optimize your process audits? Contact us today to learn how QW6 can enhance your process monitoring strategy.