Chapter 14: Internal Audits & Quality Improvement Programs
📘 1. What are Internal Quality Audits?
An Internal Quality Audit is a systematic, independent review conducted within an organization to evaluate whether processes:
Comply with quality standards (e.g., ISO 9001)
Are effectively implemented and maintainedHelp in achieving quality objectives
🔍 Key Characteristics:
Done by internal team (not external certifying body)
Planned, scheduled, and documentedFocused on process conformance, not just product defects
📊 2. Types of Quality Audits
| Type | Purpose | Example |
|---|---|---|
| System Audit | Checks the quality system's structure (ISO 9001) | Is the company following ISO procedures? |
| Process Audit | Examines how a specific process is carried out | Welding process audit |
| Product Audit | Checks if final product meets specs | Dimension and surface test of a shaft |
| Follow-up Audit | Verifies if corrective actions were effective | Re-audit of previous NCR area |
📋 3. Audit Life Cycle
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Planning: Define scope, team, and schedule
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Execution: On-site data collection, interviews, checklist review
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Reporting: Record observations – NCRs (Non-Conformance Reports) or OFIs (Opportunities for Improvement)
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Corrective Action Request (CAR): Departments take action
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Follow-up: Verify effectiveness of actions
🛠️ 4. Real-World Example:
Scenario:
During an internal audit of a fabrication shop, it was found that welding machines were not calibrated as per schedule.
NCR Issued
Root Cause: Maintenance team unaware of scheduleCorrective Action: Maintenance schedule displayed on machines
Follow-Up: Verified calibration in next audit
🚀 5. What is a Quality Improvement Program (QIP)?
It’s a systematic, long-term approach aimed at reducing defects, waste, and rework while improving product and process quality.
🔧 Tools used in QIP:
Six Sigma (DMAIC)
Lean ManufacturingPDCA (Plan-Do-Check-Act) Cycle
Kaizen (Continuous Improvement)
Benchmarking
🎯 6. Benefits of QIP in Mechanical Industry
Increased equipment uptime
Fewer customer complaintsReduced inspection costs
Stronger process control
Improved customer confidence
🏭 Industrial Case Example:
In a valve manufacturing plant, frequent leakage failures were observed.
QIP launched using DMAIC
Root cause: Incorrect lapping of valve seatAction: Upgraded lapping tools and retrained operators
Result: 40% drop in leakage complaints within 2 months
⚠️ Common Challenges in Internal Audits/QIP
| Challenge | Solution |
|---|---|
| Resistance from production staff | Explain audit benefits and involve them early |
| Unclear documentation | Standardize formats and train auditors |
| Lack of follow-up | Assign clear responsibilities for CARs |
| Shortage of skilled auditors | Train internal teams or hire temporarily |
📌 Field Application Tips:
Always keep auditor checklists and evidence logs organized.
Use data and KPIs to back audit observations.Rotate auditors to avoid bias.
Use audit findings to fuel improvement projects, not just compliance.
Chapter 14: Quiz – Internal Audits & QIP
Q1. What is the main purpose of an internal quality audit?
A) To punish employees for mistakes
B) To evaluate product sales
C) To verify process compliance and effectiveness
D) To prepare tax documents
🟩 Correct Answer: C
Q2. Which of the following is not a type of quality audit?
A) System Audit
B) Product Audit
C) Process Audit
D) Marketing Audit
🟩 Correct Answer: D
Q3. In audit terminology, what does NCR stand for?
A) Non-Corrective Request
B) Non-Compliance Regulation
C) Non-Conformance Report
D) Normal Control Record
🟩 Correct Answer: C
Q4. What is the primary goal of a Quality Improvement Program (QIP)?
A) To improve salaries
B) To reduce waste and improve processes
C) To increase the number of audits
D) To decrease product prices
🟩 Correct Answer: B
Q5. Which quality tool is based on continuous improvement philosophy?
A) Gantt Chart
B) Pareto Analysis
C) Kaizen
D) Venn Diagram
🟩 Correct Answer: C
Q6. What does PDCA stand for in quality management?
A) Plan-Design-Control-Apply
B) Plan-Do-Check-Act
C) Predict-Design-Check-Action
D) Perform-Develop-Control-Apply
🟩 Correct Answer: B
Q7. A follow-up audit is conducted to:
A) Add more paperwork
B) Close the client deal
C) Check if corrective actions were implemented
D) Celebrate project completion
🟩 Correct Answer: C
Q8. Which of the following is a valid audit finding?
A) Gossip
B) Verbal complaints
C) Evidence-based nonconformance
D) Hearsay
🟩 Correct Answer: C
Q9. What is a major benefit of internal audits in a mechanical workshop?
A) Less workload for operators
B) Identifying potential failures early
C) Ignoring standards
D) Speeding up client visits
🟩 Correct Answer: B
Q10. In Six Sigma, what does DMAIC stand for?
A) Define, Measure, Analyze, Improve, Control
B) Design, Measure, Apply, Innovate, Control
C) Develop, Maintain, Assess, Implement, Check
D) Document, Model, Approve, Implement, Change
🟩 Correct Answer: A