1.The check items shown on the left side column and the
upper column have document characteristics.
Table1 shows an example of a weekly checklist for Machine A. It
is used monthly. Check items has four items. The upper column indicates
weekly check interval. Who made this decision? Who did approve and
review the content? If one item add to present four items, how to
handle with this change?
It means the left column and the upper column have to be under document
control (4.2.3 clause of ISO9001: 2000). Thus the columns for draft,
review and approval is placed on the upper right of the paper. What
are to be reviewed and approved are the check items on the left
side column and weekly check interval on the upper column side only.
Table1
| Machine checklist
Approval |
Review |
Draft |
Toby |
Percy |
Tom |
04.05.10 |
Machine
‚`@ month@@year
Check
item |
Check
recordiWeeklyj |
| 1‚v |
2‚v |
3‚v |
4‚v |
5‚v |
| a |
|
|
|
|
|
| b |
|
|
|
|
|
| c |
|
|
|
|
|
| d |
|
|
|
|
|
| Operator |
|
|
|
|
|
|
2. The check records shown on the right side column have
record characteristics.
According to the checklist, a person in charge of Machine A will
check four items weekly and enter check markƒŒ in
the column. The results provide evidence of activities performed.
Therefore, the right side of the paper is for record, not document
referred to 4.2.3. When an operator enters in the check results,
the paper changes from a document to a record.
3. Needs to make distinction between document and record
clearly
Thus the paper has both characteristics of document and record,
according to each column. So if you have no clear understanding
of distinction between document and record, you will fail to do
the right entry. The saying like records are a special type of document
is ambiguous and it easily causes confusion on an actual entry in
the paper.
I often encounter on a scene that an operator uses the paper with
no sign of review and approval in each column. Then after record
entry, a shop manager signed in the upper column to show his confirmation.
It is a typical example to show misunderstanding of document and
record.
4. Distinction between approval and confirmation
Following figure shows the difference between document and record.
According to above figure, you can make clear distinction between
approval and confirmation as shown in Table2, to avoid loss caused
by the confusion.
Table2
| Machine checklist
Approval |
Review |
Draft |
Toby |
Percy |
Tom |
04.05.10 |
Machine
‚`@ June 04@
Check
item |
Check
recordiWeeklyj |
| 1‚v |
2‚v |
3‚v |
4‚v |
5‚v |
| a |
ƒŒ |
|
|
|
|
| b |
ƒŒ |
|
|
|
|
| c |
ƒŒ |
|
|
|
|
| d |
ƒŒ |
|
|
|
|
Operator |
John |
|
|
|
|
| Confirmation |
Bill |
|
|
|
|
|
5. Lack of management in TPM
In Japan, TPM (Total Preventive Maintenance) promotes g independent
machine checkh by a machine operator. Therefore there is no column
for approval by authority. Generally a shop leader has its master
list.
By chance I found in a factory a difference between check items
of an operatorfs checklist and its master, which his shop leader
had. The operatorfs checklist had seven items to check, but the
master had nine. I found the different two items had added in the
master about one and half year before. That meant the operatorfs
checklist had been left no revised for one and a half year until
I found the difference.
The reason was that there was no system to check between the both
checklist and the shop leader had not interested in the operatorfs
checklist due to independent concept.
Every day they had met, but no conversation about machine check.
No shop management!
In the case of ISO9001: 2000 an operator cannot use a checklist
without approval by some authority.