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ISO 9001:2008

Bureau Veritas Certification

Management System Certification
Audit Report for the Re-Certification Audit
Of QMS ISO9001:2008

PT. TOYOPLAS MANUFACTURING INDONESIA

Company Information
Company Name PT. TOYOPLAS MANUFACTURING INDONESIA

Address Jl. Trembesi Blok F5, No. 9, Delta Silicon II, Lippo Cikarang Bekasi – 17550, Jawa Barat – INDONESIA

Phone No. 62-21- 8911 7301-07 Fax No. 62-21-8911 7808/55.
Web Address http://www.toyoplas.com

ZIG Contract No(s).
Contact Information
Contact Name Mr. Ben Chan/Mr. Yulianus Dionys M Phone No. 0813-8582 0410
Email Address dony@toyoplas.co.id ;iso.team@toyoplas.co.id

Audit Information
Audit Standard(s) QMS ISO9001:2008

Industry Code(s) 14B
No. of Employees 2400 employees No. of Shifts 3 (three)
Audit Type Re-Certification Audit

Audit start date January 25, 2010 Audit end date January 26, 2010
Next Audit Date Date stated Duration As per SF 17
Auditor Information
Team Leader Mr. Surya K. Basnur (SKB)
Team Member Mr. Olrah Patinama (OAP) ; Mr. Nendra Gunawan (NGN) ; Mr. Herry Priyono (HPY)
Shift Pattern I

If this is a multi-site audit an Appendix listing all the relevant sites and/or remote locations has been established and attached to the audit report.

Distribution PT. TOYOPLAS MANUFACTURING INDONESIA / Audit Team /BV Certification office

Summary of Audit Findings:
Number of Non Conformities recorded: Major: Nil (0) Minor: Four
( 4 )
Is a follow up audit required? Y/N Follow up audit start date day(s)
Actual follow up date(s) Start: End:
Follow-up audit remarks:
Team Leader Recommendation:
Standard Recommendation
QMS ISO9001:2008

1 Granted,

0 Continued,

0 Withheld/Suspended until satisfactory corrective action is completed.

Team Leader (1): Team Member
Mr. Surya K. Basnur (SKB)
1. Mr. Olrah Patinama (OAP)
2. Mr. Nendra Gunawan (NGN)
3. Mr. Herry Priyono (HPY)
4. N/A
Scope of Supply (scope statement must be verified and appear in the space below)
INJECTION MOLDING OF PLASTICS, FINISHING AND ASSEMBLY OF MECHANICAL
COMPONENTS AND PCB ASSEMBLY FOR CONSUMER ELECTRONIC & AUTOMOTIVE
Accreditation UKAS
No. of Certs required 1
Languages English
Reason for Issue of Certificate 0 New Certificate
1 Re-Certification
0 Additional Scope

Further Instructions (additonal certificate instruction or information for the office) :
Specify changes in the organization (scope, number of employees, sites, management, organization…)

Audit Summary

Audit Objectives
The objectives of this audit are :

1. to confirm that the mangement system conforms with all the requirements of the audit standard;
2. to confirm that the organisation has effectively implemented its planned arrangements;
3. to confirm that the management system is capable of achieving the organisation’s policies objectives.

Previous Audit Results
The results of the last audit of this system have been reviewed, in particular to assure appropriate correction and corrective action has been implemented to address any nonconformity identified.

No. of nonconformities from previous audit Major 0 Minor 0
No. of nonconformities closed Major 0 Minor 0
No. of nonconformities re-raised Major 0 Minor 0

This review has concluded that:

– any nonconformity identified during previous audits has been corrected and the corrective action continues to be effective.

– the management system has not adequately addressed nonconformity identified during previous audit activities and the specific issue has been re-defined in the nonconformity section of this report.

– the organization’s system for registering Customer Complaints, performing Corrective and Preventive Actions and closing out the Customer Complaints was reviewed and found to be satisfactory.

Audit Findings
The audit team conducted a process-based audit focussing on the sigificant aspects, risks and objectives. The audit method used were interviews, observations of activities and review of documentation and records.

• The management system documentation demonstrated conformity with the requirements of the audit standard and provided sufficient structure to support implementation and maintenance of the management system,
• The organisation has demonstrated effective implementation and maintenance / improvement of its management system.
• The organisation has demonstrated the establishment and tracking of appropriate key performance objectives and targets and monitored progress towards their achievement,
• The internal audit programme has been fully implemented and demonstrates effectiveness as a tool for maintaining and improving the management system,
• Throughout the audit process, the management system demonstrated overall conformance with the requirements of the audit standard.

Nonconformities
Nonconformities detailed herein shall be addressed through the organisation’s corrective action process, in accordance with the relevant corrective action requirements of the audit standard, in actions to prevent reccurence, and complete records maintained.

Corrective actions to address identified major nonconformities shall be carried out immediately and BV Certification notified of the actions within 30 days. Our auditor will perform a follow up visit within 90 days to confirm the actions taken, evaluate their effectiveness, and determine wether certification can be granted or continued.

Corrective action to address identified minor nonconformities shall be carried out and records maintained with supporting evidence.

The responses to the nonconformities may be either in hard copy or electronically using the NCR herein (preferred) and forwarded to the BV Certification office.

At the next scheduled audit visit, the BV Certification audit team will follow-up on all identified nonconformities to confirm the effectiveness of the corrective actions taken and close out.

Observations (Weakness)
An area of concern, a process, document, or activity that is currently conforming that may if not improved, result in a nonconforming system, product or service.

Opportunities for Improvement (Comment)
A process/activity/document that, while currently conforming, could be improved to bring benefit to the client.

Recommendation
The audit team conducted a process-based audit focussing on significant aspects/risks and objectives required by the standard(s). The audit methods used were interviews, observations, sampling of activities and review of documentation and records.

The structure of the audit was in accordance with the audit plan and audit planning matrix included in the Appendices to this summary report.

The audit team concludes that the organisation has/has not established and maintained its management system in line with the requirements of the standard(s) and demonstrated the ability of the system to achieve requirements for products and/or services within the scope and the organisation’s policy and objectives.

Therefore the audit team recommends that, based on the results of this audit and the system’s demonstrated state of development and maturity, that this management system certification be
• Processed subject to a satisfactory corrective action plan
• Continued subject to a satisfactory corrective action plan
• Suspended until a satisfactory corrective action is completed
• Withdrawn (your attention drawn to the Appeals Procedure defined in the Conditions of Contract)

This report is confidential and distribution is limited to the audit team, the company and the BV Certification office.

AUDIT SUMMARY REPORT FOR ISO 9001:2000

Exclusions / Justification Process / Acivity / Department
7.3 : Design and or development Doc Rev MR / DCC / Internal Audit Engineering (Include Tooling) QA/QC PCB Assy Moulding Process Secondary Process Procurement (Include Material Store) IT HR & GA NCR

T
O
T
A
L
S
7.5.2 : Validation of Service Compliant (Y/N)
See comments below

Clause Description
4.1 General Requirements Y X X X X X X X X X
4.2 General Documentation Requirements Y X X X X X X X X X
5.1 Management commitment Y X
5.2 Customer Focus Y X
5.3 Quality policy Y X X X X X X X X X
5.4 Planning Y X X X X X X X X X
5.5 Responsibility, authority and communication Y X X X X X X X X X
5.6 Management Review Y X
6.1 Provision of resources Y X X
6.2 Human resources Y X
6.3 Infrastructure Y X 1 1
6.4 Work environment Y
7.1 Planning of Product Realization Y
7.2 Customer-related processes Y X
7.3 Design and or development N E X C L U D E D
7.4 Purchasing Y
7.5.1 Control of Production and Service Y X 1 1 2
7.5.2 Validation of Service N E X C L U D E D
7.5.3 Identification and Traceability Y X
7.5.4 Customer Property Y
7.5.5 Preservation of Product Y X X
7.6 Control of measuring and monitoring devices Y 1 1
8.1 General Y X X X X X X X X X
8.2.1 Customer Satisfaction Y X
8.2.2 Internal audit Y X
8.2.3 Measurement and monitoring of processes Y X X X X X X X X X
8.2.4 Measurement and monitoring of product Y X X X
8.3 Control of Nonconformant Product Y X
8.4 Analysis of Data Y X X
8.5.1 Continual improvement Y X X X X X X X X X
8.5.2 Corrective action Y X X X X X X X X X
8.5.3 Preventive action Y X X X X X X X X X
Use of Logo’s Y X
Document Review remarks :
Certification Request / Document Review :
Quality manual has already compliance and completely with standard and process

AUDIT SUMMARY REPORT FOR ISO 9001:2000

Exclusions / Justification Process / Acivity / Department
7.3 : Design and or development Doc Rev Production Planning Warehouse NCR

T
O
T
A
L
S
7.5.2 : Validation of Service Compliant (Y/N)
See comments below

Clause Description
4.1 General Requirements Y X X
4.2 General Documentation Requirements Y X X
5.1 Management commitment Y
5.2 Customer Focus Y
5.3 Quality policy Y X X
5.4 Planning Y X X
5.5 Responsibility, authority and communication Y
5.6 Management Review Y
6.1 Provision of resources Y
6.2 Human resources Y
6.3 Infrastructure Y
6.4 Work environment Y
7.1 Planning of Product Realization Y X
7.2 Customer-related processes Y
7.3 Design and or development N E X C L U D E D
7.4 Purchasing Y
7.5.1 Control of Production and Service Y
7.5.2 Validation of Service N E X C L U D E D
7.5.3 Identification and Traceability Y X
7.5.4 Customer Property Y X
7.5.5 Preservation of Product Y X
7.6 Control of measuring and monitoring devices Y
8.1 General Y X X
8.2.1 Customer Satisfaction Y
8.2.2 Internal audit Y
8.2.3 Measurement and monitoring of processes Y X X
8.2.4 Measurement and monitoring of product Y
8.3 Control of Nonconformant Product Y
8.4 Analysis of Data Y
8.5.1 Continual improvement Y X X
8.5.2 Corrective action Y X X
8.5.3 Preventive action Y X X
Use of Logo’s Y X
Document Review remarks :
Certification Request / Document Review :
Quality manual has already compliance and completely with standard and process

PERFORMANCE TO DATE
Visit Report Ref. Grade Date of Verification Standard
Sector / Division / Location Clause Status
January 25, 2010
0 Major
1 Minor
QMS ISO9001:2008

F I N D I N G
1 It’s Observed that there was insufficient evidence the monitoring and measuring equipment needed to provide evidence of conformity of product to determined requirement has been carried out properly as per requirement QMS ISO9001:2008 clause 7.6.
E.g.
– The related instrument (Digital Calliper and Digital Micrometer) at Tooling Department to control dimension of part modification was not evidence already calibrated to have accurate data.
– The factor correction from data external calibration result was not communicated to user, this is critical condition for data measurement of dimension part if the factor correction have significant value. Tooling 7.6 0 Close
0 Open

2 It’s observed that there was inssuficient evidence the control of room temperature at PCB Assy area has been carried out properly since augustus 2009 as per standard room temperature (22oC – 28oC) and requirements QMS ISO9001:2008 clause 7.5.1. PCB Assy 7.5.1 0 Close
0 Open

3 It was found that a number of daily production records at December 2009 have not been checked and verified by related Leader and Supervisor signature (form TMI-PRD-F-006-rev 00) as mentioned by Production process flowchart page 12 of 14 Injection Moulding process procedure. Moulding Process 7.5.1 0 Close
0 Open

4 It’s Observed that there was insufficient evidence the maintain of information system by organization has been carried out properly as per requirement QMS ISO9001:2008 clause 6.3 E.g. system of back up data, hardware/software maintenance and repair; troubleshooting and also security system . IT 6.3 0 Close
0 Open

TO BE COMPLETED BY BV NON CONFORMITY REPORT
DATE ORGANIZATION FILE REF REPORT No
January 25, 2010 PT. TOYOPLAS MANUFACTURING INDONESIA

(SKB)/ 1 of 2

Jl. Trembesi Blok F5, No. 9, Delta Silicon II, Lippo Cikarang Bekasi – 17550, Jawa Barat – INDONESIA

NON CONFORMITY OBSERVED DURING Re-Certification Audit

NON CONFORMITY OBSERVED IN PROCESS Tooling

Standard and Clause#: QMS ISO9001:2008
7.6

NON CONFORMITY – DESCRIPTION OF OBJECTIVE EVIDENCE :
It’s Observed that there was insufficient evidence the monitoring and measuring equipment needed to provide evidence of conformity of product to determined requirement has been carried out properly as per requirement QMS ISO9001:2008 clause 7.6.
E.g.
– The related instrument (Digital Calliper and Digital Micrometer) at Tooling Department to control dimension of part modification was not evidence already calibrated to have accurate data.
– The factor correction from data external calibration result was not communicated to user, this is critical condition for data measurement of dimension part if the factor correction have significant value.

GRADE LEAD ASSESSOR ASSESSOR ORGANIZATION REP.
0 Major 1 Minor
Mr. Surya K. Basnur (SKB)
Mr. Olrah Patinama (OAP)
Error! Reference source not found.

Mr. Nendra Gunawan (NGN)

TO BE COMPLETED BEFORE Mr. Herry Priyono (HPY)

N/A

TO BE COMPLETED BY THE ORGANIZATION ROOT CAUSE ANALYSIS (What failed in the system to allow this NC to occur ?)

CORRECTIVE ACTION (What is done to solve this problem and to prevent recurrence)

VERIFICATION OF CORRECTIVE ACTIONS DATE OF COMPLETION
ORGANIZATION REPRESENTATIVE Error! Reference source not found.

TO BE COMPLETED BY BV VERIFICATION OF CORRECTIVE ACTIONS DATE STATUS ASSESSOR

AUDITOR COMMENTS

TO BE COMPLETED BY BV NON CONFORMITY REPORT
DATE ORGANIZATION FILE REF REPORT No
January 25, 2010 PT. TOYOPLAS MANUFACTURING INDONESIA

(SKB)/ 2of 2

Jl. Trembesi Blok F5, No. 9, Delta Silicon II, Lippo Cikarang Bekasi – 17550, Jawa Barat – INDONESIA

NON CONFORMITY OBSERVED DURING Re-Certification Audit

NON CONFORMITY OBSERVED IN PROCESS PCB Assy

Standard and Clause#: QMS ISO9001:2008
7.5.1

NON CONFORMITY – DESCRIPTION OF OBJECTIVE EVIDENCE :
It’s observed that there was inssuficient evidence the control of room temperature at PCB Assy area has been carried out properly since augustus 2009 as per standard room temperature (22oC – 28oC) and requirements QMS ISO9001:2008 clause 7.5.1.

GRADE LEAD ASSESSOR ASSESSOR ORGANIZATION REP.
0 Major 1 Minor
Mr. Surya K. Basnur (SKB)
Mr. Olrah Patinama (OAP)
Error! Reference source not found.

Mr. Nendra Gunawan (NGN)

TO BE COMPLETED BEFORE Mr. Herry Priyono (HPY)

N/A

TO BE COMPLETED BY THE ORGANIZATION ROOT CAUSE ANALYSIS (What failed in the system to allow this NC to occur ?)

CORRECTIVE ACTION (What is done to solve this problem and to prevent recurrence)

VERIFICATION OF CORRECTIVE ACTIONS DATE OF COMPLETION
ORGANIZATION REPRESENTATIVE Error! Reference source not found.

TO BE COMPLETED BY BV VERIFICATION OF CORRECTIVE ACTIONS DATE STATUS ASSESSOR

AUDITOR COMMENTS

TO BE COMPLETED BY BV NON CONFORMITY REPORT
DATE ORGANIZATION FILE REF REPORT No
January 25, 2010 PT. TOYOPLAS MANUFACTURING INDONESIA

(OAP) 1 of 1
Jl. Trembesi Blok F5, No. 9, Delta Silicon II, Lippo Cikarang Bekasi – 17550, Jawa Barat – INDONESIA

NON CONFORMITY OBSERVED DURING Re-Certification Audit

NON CONFORMITY OBSERVED IN PROCESS Moulding Process

Standard and Clause#: QMS ISO9001:2008
7.5.1

NON CONFORMITY – DESCRIPTION OF OBJECTIVE EVIDENCE :
It was found that a number of daily production records at December 2009 have not been checked and verified by related Leader and Supervisor signature (form TMI-PRD-F-006-rev 00) as mentioned by Production process flowchart page 12 of 14 Injection Moulding process procedure.

GRADE LEAD ASSESSOR ASSESSOR ORGANIZATION REP.
0 Major 1 Minor
Mr. Surya K. Basnur (SKB)
Mr. Olrah Patinama (OAP)
Error! Reference source not found.

Mr. Nendra Gunawan (NGN)

TO BE COMPLETED BEFORE Mr. Herry Priyono (HPY)

N/A

TO BE COMPLETED BY THE ORGANIZATION ROOT CAUSE ANALYSIS (What failed in the system to allow this NC to occur ?)

CORRECTIVE ACTION (What is done to solve this problem and to prevent recurrence)

VERIFICATION OF CORRECTIVE ACTIONS DATE OF COMPLETION
ORGANIZATION REPRESENTATIVE Error! Reference source not found.

TO BE COMPLETED BY BV VERIFICATION OF CORRECTIVE ACTIONS DATE STATUS ASSESSOR

AUDITOR COMMENTS

TO BE COMPLETED BY BV NON CONFORMITY REPORT
DATE ORGANIZATION FILE REF REPORT No
January 25, 2010 PT. TOYOPLAS MANUFACTURING INDONESIA

(NGN) / 1 of 1
Jl. Trembesi Blok F5, No. 9, Delta Silicon II, Lippo Cikarang Bekasi – 17550, Jawa Barat – INDONESIA

NON CONFORMITY OBSERVED DURING Re-Certification Audit

NON CONFORMITY OBSERVED IN PROCESS IT
Standard and Clause#: QMS ISO9001:2008
6.3
NON CONFORMITY – DESCRIPTION OF OBJECTIVE EVIDENCE :
It’s Observed that there was insufficient evidence the maintain of information system by organization has been carried out properly as per requirement QMS ISO9001:2008 clause 6.3 E.g. system of back up data, hardware/software maintenance and repair; troubleshooting and also security system
GRADE LEAD ASSESSOR ASSESSOR ORGANIZATION REP.
0 Major 1 Minor
Mr. Surya K. Basnur (SKB)
Mr. Olrah Patinama (OAP)
Error! Reference source not found.

Mr. Nendra Gunawan (NGN)

TO BE COMPLETED BEFORE Mr. Herry Priyono (HPY)

N/A

TO BE COMPLETED BY THE ORGANIZATION ROOT CAUSE ANALYSIS (What failed in the system to allow this NC to occur ?)

CORRECTIVE ACTION (What is done to solve this problem and to prevent recurrence)

VERIFICATION OF CORRECTIVE ACTIONS DATE OF COMPLETION
ORGANIZATION REPRESENTATIVE Error! Reference source not found.

TO BE COMPLETED BY BV VERIFICATION OF CORRECTIVE ACTIONS DATE STATUS ASSESSOR

AUDITOR COMMENTS

Comments on: "ISO 9001:2008" (2)

  1. Nice share. Thank you for this😉

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