Frank Pokrop BD Becton Dickinson and Co. · Frank Pokrop BD –Becton Dickinson and Co. ... Goals...
Transcript of Frank Pokrop BD Becton Dickinson and Co. · Frank Pokrop BD –Becton Dickinson and Co. ... Goals...
AGENDA
1. Welcome –
2. Introductions
3. As We Begin
4. Goals for Today’s Talk
5. Why ASQ is Important
6. What is Auditing and Basics?
7. When is an Audit Effective?
8. Measuring Audit Criteria
9. How Many Types of Audits are
There?
10. The Science
11. The Art
12. The Value of an Independent
Eye, or How to Use Your
Auditors
13. Risk
14. Becoming an auditor
15. The Value of a Corporate Audit
Function
3. As We Begin:
• Thank You!
• Today’s Presentation
• ASQ Test Prep?
• About me
• “Q&A” At Any Time
• About You – A Few Questions
S AN D I EGO ASQ - Auditing – Science, Art and More
4. Goals for Today’s Talk:
a. Education, hopefully
b. “Frank” discussion
c. Identify creative and constructive uses of audits
and auditor assignments
d. See the role that risk now plays in our lives:
i. Cost and product impact
ii. Patient and user
iii. Selection of audit sites and target
S AN D I EGO ASQ - Auditing – Science, Art and More
4. Goals for Today’s Talk:
e. Understanding:
i. VUCA (Volatility, Uncertainty, Complexity, and Ambiguity)
ii. Risk Based Thinking
f. Risk-Based Thinking
i. New Topic, or,
• ISO 9001: 2015
• ISO 13485: 2016
• ?
S AN D I EGO ASQ - Auditing – Science, Art and More
4. Goals for Today’s Talk:
g) The value of Corporate auditing – or just independence?
S AN D I EGO A SQ - Auditing – Science, Art and More
5. Why ASQ is Important
a. Personal and professional growth
b. Value to you, your family and profession
c. Learning and insights into many things,
processes, companies, issues, etc.
6. What is Auditing, and basics?
http://www.theiia.org
"Internal auditing is an independent, objective assurance and
consulting activity designed to add value and improve an
organization's operations.
It helps an organization accomplish its objectives by bringing a
systematic, disciplined approach to evaluate and improve the
effectiveness of risk management, control, and governance
processes."
S AN D I EGO A SQ - Auditing – Science, Art and More
6. What is Auditing?
a. Many, many good definitions
b. Walks like a duck….
c. Determines state of compliance with rules,
regulations, standards, industry-wide tests….
An expected level of performance
d. ASQ / ISO defined elements… formal,
announced, sponsor, etc.
e. Formal comparison against internal
expectations, external requirements and
customer needs
f. Non-standard, special request type of
examination…
S AN D I EGO A SQ - Auditing – Science, Art and More
The Goal Of An Audit:
- To Collect Objective Evidence
- To Permit An Informed Judgment About The
Status Of The Systems or Product Being Audited
Remember that Audits Have Formal Parts, Formal Requirements and a Formal Process
ISO 19011:2011—Guidelines for auditing management systems(see handouts)
Phases of an audit:
1. Audit preparation
2. Audit performance
3. Audit reporting
4. Audit follow-up and closure
http://asq.org/learn-about-quality/auditing/
A u d i t P r o g r a m / A u d i t L i f e c y c l e F l o w C h a r t
Develop resource plan
Write discrete audit plan
Perform audit: report to functional mgmt.
Enter non-conformities into CAPA system
Functional mgmt.takes ownership of CAPA response
Measure audit effectiveness
Develop and approve audit schedule
Audit Findings: (6.4.7)
Audit evidence should be evaluated against the audit criteria in order to determine audit findings. Audit findings can indicate conformity or nonconformity with audit criteria. When specified by the audit plan, individual audit findings should include conformity and good practices along with their supporting evidence, opportunities for improvement, and any recommendations to the auditee.
Nonconformities and their supporting audit evidence should be recorded. Nonconformities may be graded. They should be reviewed with the auditee in order to obtain acknowledgement that the audit evidence is accurate, and that the nonconformities are understood. Every attempt should be made to resolve any diverging opinions concerning the audit evidence or findings, and unresolved points should be recorded.
Audit Findings:
• A well-written audit finding provides the auditee
with enough information to act on and to correct
or prevent a reoccurrence.
The Audit Report:
1. Cover page or logistics header: contextual information that characterizes the report.
2. Introduction and background: information regarding the purpose and scope that was contained in either the audit plan or notification letter.
3. Results and summary: the overall conclusions and recommendations.
4. Detailed results: a listing of all findings.
5. Appendix: supplemental information that might explain or clarify the information contained in the report.
http://asq.org/quality-progress/2007/06/auditing/preparing-and-structuring-audit-report.html
Writing an audit report + ranking
a. Clear, consistent, spell-checked, formatted,
quantitative, qualitative, respectful, thankful,
reviewed (hint: independent eye)
b. Lists the site, location, dates, auditors, type of audit,
scope and other audit formalities
c. Show the conclusions, ranking, number of
observations by different severities, due date for
responses and corrective actions
Writing an audit report + ranking
d. Cites the as-found condition including qualitative and
quantitative observations and supporting data
e. Compares the finding against one or more standards,
rules or regulations
f. Ranks the severity
Risk might be used in (see handouts):
• Audit observations
• Audit reports
• Site conclusions
• Scheduling
• Priority
QS ASSESSMENT SCORECARD (Risk) High LOW
Criteria 1 2 3 4 5
Quality System:
Change X
Influence & Deployment X
Harmonization Status (BQSR Matrix) X
Product:
Risk Management (Clinical Significance) X
Changes to Product X
Regulatory Status:
Recall Classification
Functional Product Issues Not Addressed: (Production Processes and Design Controls)
Organizational Effectiveness:
Organizational Support X
Quality Organization X
Capabilities:
Manufacturing (N/A)
Engineering (N/A)
Supplier Management (N/A)
Business Influences:
Growth X
New Products X
Relocating X
Expansion X
Low Profit X
Improvement Process:
Quality Organization Capability X
Improvement Since Last Audit (N/A)
Compliance Culture X
7. When is an Audit Effective?
a. When the president gets the report
i. Who decides who sees the report?
b. When change takes place?
c. When compliance is increased?
d. When enforcement takes place?
e. When recalls decrease?
f. Role of the customer?
g. Remember to measure every aspect of an audit
When is an Audit Effective?
a. When the president gets the
report
i. Who decides who sees the
report?
b. When change takes place?
c. When compliance is increased?
d. When enforcement takes place?
e. When recalls decrease?
f. Role of the customer?
g. Remember to measure every
aspect of an audit
- Dynamic views….
- Changes with leadership
- Changes with time
- Cost measures
- Compliance status
- Audit frequency changes
- Company goals
- Insurance and liability
- Specific observations
are resolved, or……..
8. Remember to measure every aspect of an audit – see handouts
• Audits / year
• Observations: number – by site, by product, by
category, by severity, type, trends, time to close,
number- corporate, year-to-year comparisons
• Sites audited / Sites not audited
• Frequency
• Re-scheduled or cancelled
• Risk rankings by………….
• Product
• Process
• Management
• Agency Approval
• Agency Approval – spec limits
• Directed
• Requested
• Lifecycle
• Utility
• Product returns
• Gov’t document
9. How Many Types of Audits are There?
Internal
External
Compliance
Enforcement (FDA, DEA)
Complaints
R&D
Project
System
Bottom-up
Top-down
System
• Country
• Process Deviation
• Aviation failure
• IT
• Installation and Repair
• Field Service
• Training
• Vendor
• Service
• Third-party contractor
• Raw material
• Laboratory
• ?
10. The Science (consistent, scientific approach)
Phases of Auditing
• Planning and Preparing for the audit
• Execution of the audit plan
• Reporting the audit results
• Close out of corrective actions
The Visible Part of Auditing:
• Opening Meeting
• Collection of Information
• Record and Grade Nonconformances
• Evaluation of Number and Significance of
Nonconformances
• Assessment of Compliance to Requirements
• Preparation of Findings
• Closing Meeting Review
Scheduling:
• Site
• Product
• Division
• Corporate
10. The Science – as an Auditor:
a. Scientific background
b. Detailed
c. Inquisitive nature
d. Consistent approach
e. Understands technology, organizations, documentation,
standards and how the product works
f. Preparation is the key to an effective audit
11. The Art:
a. Question: how to be effective in every audit?
b. Answers:
i. Preparation + team input + consistency
ii. Not using the same approach too often
iii. Team and individual review before starting an audit
iv. Alternating duties and roles (leader, auditor, site)
v. Changing the focus
vi. Changing the makeup of the auditing team
i. Guest auditor (development role)
ii. Guest expert
11. The Art – questions:
a. What hasn’t been audited at this site?
b. Changing your starting points
c. Reviewing external data
d. Watching the practices and processes
e. Developing new or additional questions for a specific audit
f. Value in the writing the “other audit report”
12. The Value of an Independent Eye, or How
to Use Your Auditors:
a. Standards – numerous examples
b. System:
a. Hardware/electrical - reviewing
engineering runs
b. Paper-based system examinations
c. Benchmarking – evaluating weaknesses
d. Site audit preparation
The Growth of Standards
• “audit” = 757 standards
• “audit checklist” = 12 standards
• “risk” = 2, 525 standards
• “quality audit” = 108 standards
• “compliance” = 3,533 standards
• “compliance audit” = 14 standards
12. The Value of an Independent Eye, or How
to Use Your Auditors:
a. Aviation examples
b. Medical device examples
c. Examples of cars
d. Your examples
13. Risk:
a. See handouts for examples
b. ISO 9001/ ISO 13485 (RBT)
i. Risk in every activity
ii. Risk of not performing an activity
correctly must be known (documented
too?)
iii. Risk in various audit activities: site, plant
corporate??? What else?
iv. How have you documented this?
• Curious
• Disciplined
• Understands science
• Structured
• Can shift between qualitative
and quantitative topics
14. Becoming an auditor
Some industry experience
Can build rapport but not
friendship
Familiar with auditing tools
and can shift gears
Schedule
From the FDA’s “Case for
Quality” report….
Relevance & value:
- Significant industry input
- Moderated by McKinsey
- Qualitative and quantitative
15. The Value of a Corporate Audit Function
Firms with an independent
corporate auditing function
have a better compliance
profile than those
companies that don’t
SAN D IEGO ASQ
T h a n k Yo u !
Frank Pokrop
CareFusion, Inc.
(858) 617-4364