How to audit whether flagged defects were actually removed
Compare the metres, not whether the machine ran. One missing comparison means it is not finished. A sample audit is fine, but the method must be written.
To audit whether a flagged defect was actually removed, match the metres on the defect map with the metres on the rewind record. If they match and a removal is written, that item counts as done. Seeing that the rewinder ran does not prove a sort happened.
Why it is judged this way
Each week pull a few flagged rolls and ask three questions: is the map there, is the rewind record there, and do the metres match. If a sample does not match, that week’s release path has a hole. Do not deal only with that one roll.
What to compare
| What you see | What to call it | What not to do |
|---|---|---|
| The metres match and a removal is written | This roll passes the audit | Only look at a signature |
| The map has no such roll | The inspection record is missing | Assume there was no defect |
| The recorded metres do not match | Fix the process first | Change the numbers on this roll |
At job change or when a roll is opened
- Each week, pull a few rolls that have flags.
- Compare the two sets of metres.
- If they do not match, change the process, not the numbers.
