Template

Assembly Process Audit Checklist

by HCE SRL, from the Community

20+

Evaluate assembly operations with this process audit checklist covering Method, Man, Machine, and Material. Check visible SOPs and OPLs, correct use and calibration of torque tools, risk controls and error-proofing, operator training and self-checks, control charts, and adherence to standard work. Inspect workstation safety, lighting, cleanliness, maintenance plans, and measurement equipment calibration. Verify material identification, packaging, cleanliness, BOM conformity, segregation of nonconforming items, and cosmetic requirements.

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With SafetyCulture you can

Digitize any process, procedure or policy

Eliminate mistakes made by paper-based processes

Create and share professional reports instantly

Confirm accountability and compliance with a digital log

About author

Community

This community page makes available free workplace checklists and templates created by other users within the SafetyCulture community. SafetyCulture has re-published this content and where possible, has credited the original author. SafetyCulture has not verified the accuracy, reliability or suitability of any community content. You agree that your use of any of this content is in accordance with SafetyCulture’s Terms and Conditions.

Template
General Process Audit Checklist
This general process audit template supports supplier quality assurance in manufacturing. It guides auditors through questions across the 6M domains: Man, Machine, Method, Environment, Measure, and Material. Topics include change management, operator training and PPE, process validation, tool identification and maintenance, equipment backups, clear and current work instructions, problem-solving tools such as PDCA and DMAIC, and error-proofing. It also covers 5S, hazardous chemical handling and MSDS, wastewater and oil disposal, electrical safety, calibration plans, data recording and use, inventory control including FIFO, labeling and traceability, nonconforming material control, subsupplier management, and required certifications (e.g., PED, IEC, RoHS). The template concludes with sections to summarize safety, major and minor findings, and points of attention, enabling corrective actions and continual improvement.
by Jian Jiang, from the Community
Downloads: 20+
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Template
Process Audit Checklist
This process audit checklist helps teams evaluate adherence to work instructions, recordkeeping, equipment calibration and maintenance, material identification and traceability, and chemical labeling. It also covers PPE, ESD controls, line clearance, and employee training verification. Use it to document deviations, confirm correct document revisions, track lot and serial numbers, and verify preventive maintenance and calibration status. The checklist supports consistent manufacturing quality, compliance, and continuous improvement with sign-off and QA review steps.
by SafetyCulture
Downloads: 20+
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Template
Level 2 and 3 Layered Process Audit Checklist
This Level 2 and 3 Layered Process Audit checklist supports quality assurance in manufacturing, especially automotive. It covers management reviews and logs, training and operator qualification, Level 1 and Level 2 audits, PPAP and engineering change tracking, and workstation checks for 5S, PPE, materials, BOM and control plan conformance. It includes verification of dynamic control plans, first piece approvals, quality alerts, andon response, and nonconforming material control with NCMR. Sections guide error proof verification, packaging and labeling, deviation or bypass controls, daily and final inspections including GP12, gage calibration and instructions, SPC review and reaction plans, and performance charts. Maintenance PMs, safety equipment, chemical handling per SDS, used oil and universal waste areas, storage and receiving inspection, FIFO and shipping are included, plus new employee safety and process knowledge checks with auditor sign off.
by Ricky Shanes, from the Community
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Template
Level 2 LPA: Error Proofing, Labeling, Receiving
Apply this Level 2 Layered Process Audit checklist to verify error-proofing devices and reaction plans, confirm packaging and labeling match instructions, and review storage and receiving controls. The form guides auditors through documentation checks, fixture and process verification, FIFO and material certification review, and supplier issue status. It also includes new-employee audit questions on PPE, first-piece use, following operator instructions, and emergency and defect handling, ensuring consistent manufacturing quality and safety.
by Ricky Shanes, from the Community
Downloads: 0
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Assembly Process Audit Checklist

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