Dear vicluvsbikes,
It sounds to me as though your process works. I used a similar process in planning audits at a local environmental remediation facility that had a 3-year cycle for audits. I don't see that as being inefficient, or as needing to eat up a lot of time (if I understand correctly what you are describing).
The criticism of checklists is unfounded, in my opinion. They are a tool to help the auditor cover the necessary ground. (I sure don't want my airline pilot chucking his checklist!) True, it's difficult to measure efficiency with a checklist question - but that's not the work for which the checklist was designed.
I'd encourage you to bring an example of your system to our September membership meeting (September 18, 2007, doors open at 5:30 PM, with dinner at @6:30 and presentation at 7:00). Share it with other members before the meeting, and you'll get the feedback you are looking for.
Good luck!
Jim Turner, Welcoming Chair, Cincinnati Section 0900 ASQ