Generate an Excel workbook for manufacturing internal audit: production, BOM, stores, inventory, WIP, job work, scrap, maintenance, capex, statutory compliance and ERP controls.
| Area | Risk | Control | Test | Evidence | Cadence |
|---|---|---|---|---|---|
| Production planning and BOM | Production records, BOM standards, routing masters or yield assumptions do not reflect actual shop-floor consumption. | Approved BOM/routing master, production order approval, yield review and exception approval for over-consumption. | Compare actual consumption with BOM standards, inspect closed production orders and review product-line yield variance. | BOM master, routing master, production order, batch card, yield report, variance working and approval. | Monthly |
| Stores GRN material issue | Materials are received, inspected, issued, returned or adjusted without complete gate, GRN, QC and requisition evidence. | Gate-entry to GRN matching, QC hold/release control, stores issue against approved requisition and return recording. | Match gate entry, supplier invoice, GRN, QC release, stores issue and return note for selected items. | Gate register, GRN, QC release, stores requisition, issue slip, return note and stock ledger. | Weekly / Monthly |
| Inventory valuation and WIP | Raw material, WIP, finished goods or stores are misstated because quantity, stage, NRV or overhead absorption is wrong. | Periodic stock count, WIP stage validation, costing review and slow-moving or damaged stock provision review. | Reconcile physical count to book stock, inspect WIP stage evidence and review overhead absorption and NRV workings. | Stock count sheet, inventory ageing, WIP statement, cost sheet, overhead absorption working and NRV assessment. | Monthly / Quarterly |
| Job work subcontracting | Goods sent to job workers are not tracked, not returned in time, or are incorrectly billed, consumed or treated for GST. | Challan-wise job-work register, open-challan ageing, job-worker reconciliation and scrap/loss approval. | Reconcile material sent, received back, transferred or supplied directly, and age open challans by category. | Job-work challan, ITC-04 support, job-worker ledger, return register, ageing report and reconciliation. | Monthly |
| Scrap waste by-products | Scrap or by-product generation is understated, sold outside books, incorrectly valued or not reconciled to production. | Scrap norms, scrap sale approval, weighbridge/gate-pass control and scrap stock reconciliation. | Compare scrap generation with norms, match dispatch to invoice and receipt, and review unusual manual sales. | Scrap register, production report, weighbridge slip, gate pass, sales invoice, receipt proof and variance note. | Monthly |
| Maintenance downtime spares | Preventive maintenance gaps, repeated breakdowns or critical-spares leakage distort production, delivery and costs. | Preventive maintenance calendar, breakdown log review, critical-spares control and downtime analysis. | Inspect PM completion, repeated breakdowns, downtime impact and critical spares issue/ageing. | PM schedule, maintenance log, downtime report, spare-parts ledger, work order and closure sign-off. | Monthly / Quarterly |
| Capex CWIP fixed assets | Capex is unauthorised, wrongly capitalised, left in CWIP after readiness, or missing physical verification. | Capex approval matrix, CWIP ageing review, capitalisation checklist, asset tagging and physical verification. | Match capex to budget/PO/installation, review CWIP readiness, inspect asset tags and test disposals. | Capex note, PO, installation certificate, CWIP ageing, FAR, asset tag, disposal approval and verification sheet. | Quarterly |
| Factory compliance EHS | Factory licences, labour filings, pollution consents, hazardous material controls or safety obligations are delayed. | Compliance calendar, licence/consent tracker, EHS incident reporting and contractor compliance review. | Check filing acknowledgements, licence validity, EHS incident closure and contractor compliance evidence. | Compliance calendar, acknowledgement, licence copy, consent order, incident register and contractor records. | Monthly / Annual |
| ERP access and master data | Users can change BOM, rates, vendors, stock adjustments, production orders or back-dated entries without review. | Role-based ERP access, maker-checker for masters, leaver review and audit-log monitoring. | Review privileged users, leavers, master changes, back-dated entries and stock adjustment logs. | ERP user list, role matrix, HR exit list, master-change log, stock-adjustment log and review sign-off. | Monthly / Quarterly |
Use this with the manufacturing checklist, the inventory checklist and the monitoring rules repository.
Manufacturing internal audit has to connect physical movement, production evidence and accounting records. This workbook turns plant risks into RCM rows and separates fieldwork sheets for production, stores, stock count, WIP, job work, scrap, capex, compliance and ERP access.
The Excel export is designed as a workpaper starter. Auditors can keep sample references, evidence links, reviewer conclusions and monitoring exceptions in one file, then tailor the workbook to plant process, ERP setup, product line and approved SOW.
A CA firm is reviewing a factory with production orders, BOM standards, stores, job workers, scrap sales and open CWIP.
