Production process steps and material flow
Plain-language summary
Whether the sequence of operations and the flow of material through the plant are defined, controlled, and protect the product from mix-ups and damage.
What the clause is really asking
This sub-element controls the risk that, even with good inputs, the way material moves and is processed introduces defects — wrong sequence, missed operations, mixing of good and bad, damage in handling, or loss of traceability. A robust process flow means the right part follows the right route, is protected along the way, and cannot skip or jump steps.
What auditors look for
The auditor walks the material flow end to end and compares it to the process flow diagram and control plan. They look at how stations are sequenced and error-proofed, how nonconforming and rework material is segregated, how FIFO and identification are maintained, and how handling, storage, and transport protect the part. They test whether a part can bypass a required step or get mixed with another.
Typical evidence
Process flow diagram vs. actual layout; station sequencing and error-proofing (poka-yoke) verification; segregation areas for NC/rework; FIFO and identification practices; handling/storage/transport conditions; traceability through the flow.
How to comply — recommendations
Lay the flow out so the correct route is the easy route and skipping a step is hard or impossible — use error-proofing and verified sequencing. Keep good, suspect, and rework material clearly segregated and identified, and maintain FIFO and traceability throughout. Protect the product in handling, storage, and transport. Verify your error-proofing actually works, on a defined frequency.
Common nonconformities
Actual flow differs from the process flow diagram; error-proofing present but not verified/working; poor segregation leading to mix risk; FIFO not maintained; handling or storage causing damage or contamination; traceability broken between steps.
Related clauses
IATF 16949 8.5.1.3 (verification of job setup), 8.5.4 (preservation), 8.7 (control of nonconforming output); ISO 9001 8.5.1, 8.5.4, 8.7
Qlause provides interpretive guidance only and is not a substitute for the standard. Refer to your licensed copy of the relevant standard for the authoritative text.