iatf 16949 ford motor companyadmin.aiag.org/docs/uploads/events/presentations/s17quality/iatf... ·...
TRANSCRIPT
IATF 16949 Ford Motor Company
Requirement to Certify to IATF 16949
Copyright © 2017 Ford Motor Company
Sue Leone, Executive Director Ford Supplier Technical Assistance Requires tier 1 suppliers to become certified to IATF 16949 to meet Q1 requirements. Letter dated 22 February 2017
IATF 16949 Ford Customer Specifics
Copyright © 2017 Ford Motor Company
• Ford released CSR for IATF 16949 March 2017, effective 1 May 2017
• A cascade letter explains the changes from the ISO/TS 16949 at a high level
• Both are available on IATF
web site
IATF 16949 Ford Customer Specifics
Copyright © 2017 Ford Motor Company
Key areas with Ford customer specifics • Certification to IATF 16949 required to achieve and maintain Q1 • Corporate Responsibility aligns with Ford Terms and Conditions • Contingency plans include Supply Risk Management Operating System • Plant planning includes Capacity Planning before equipment installation • Special Characteristics are approved by Ford • Sub-tier suppliers not certified to ISO/TS or IATF 16949 use Minimum
Automotive Quality Management System Requirements for Sub-tier Suppliers (MAQMSR)
• Software developers are assessed to Automotive SPICE • Suppliers with Q1 Revoked status must notify their Certification Bodies
Transition to IATF 16949
Copyright © 2017 Ford Motor Company
Steps to a successful transition to IATF 16949
• Confirm dates for transition audit with your Certification Body
• Develop a work plan back from the date of the transition audit
• Review the requirements and provide feedback as soon as possible if there are concerns
• Allow enough time after the transition audit to address non conformances
Transition to IATF 16949
Copyright © 2017 Ford Motor Company
Where to provide feedback if challenges to transition are observed
• Suppliers: provide feedback through your National Associations (AIAG being one of them)
• Certification Bodies: provide feedback through your Oversight Offices
• OEMs: provide feedback through your representative on the IATF
Transition to IATF 16949 - Resources
Copyright © 2017 Ford Motor Company
Go to the IATF web site for the latest news, interpretations and updates
Transition to IATF 16949 - Status
Copyright © 2017 Ford Motor Company
IATF data reports the following: • 51 weeks remaining for the transition • 202 suppliers to Ford transitioned • Over 3500 certifications remaining • 70 transition audits for Ford suppliers need to take place each week before
September 2018 • With planning this is possible for all OEMs • Globally over 1200 audits need to take place each week, covering all sites • Less than 1 audit per week per auditor – with planning, this is possible • Please do not wait to confirm your transition audit date
Transition to IATF 16949 - Status
Copyright © 2017 Ford Motor Company
Questions?
Aaron A. Dodak Global Supplier Quality Manager
General Motors – Supplier Data
Top 10 QMS Failures (BIQS Elements)
IAOB Supplier Incentive • Based on Supplier data and similar data from other
OEM’s, the IAOB Steering Committee and Board of Directors recognized the need to create a workshop to both help develop suppliers while addressing significant issues that impacted their site.
• The IAOB Board of Directors approved funding this new workshop.
General Motors
The purpose is to support the development and validation of a workshop approach to address current needs in the automotive industry. Automotive suppliers are ISO/TS 16949 or IATF 16949 compliant. Yet, non-conforming errors still occur. WHY? • Is class room training effective?
Intervention Workshop
• To perform a reverse PFMEA of the issue by taking the plant team and walking the factory line, verifying PFMEA is correct and up-to-date.
• The team will check the PCP to ensure it matches the PFMEA; ensuring the PCP
frequency of checks is adequate to keep a nonconforming part from leaving the plant.
• The team will then verify Standard Work is correct and clear on how to perform the PCP checks.
This Workshop takes a hands-on approach to addressing a real problem at the source. The activity teaches the team how to become effective problem solvers.
Intervention Workshop
The Core Focus of the Workshop:
What Can Be Accomplished by Creating a Successful
Partnership with Safety and Quality as the Primary Focus?
General Motors
© 2017 - International Automotive Oversight Bureau
AIAG Quality Summit
IATF 16949:2016 Update Automotive QMS Transition
September 19, 2017
Ms. Cherie Reiche, IAOB
© 2017 - International Automotive Oversight Bureau 19
0.8%
68.2%
17.0% 2.6%
9.2%
2.2%
Africa AsiaPacific
Europe MiddleEast
NorthAmerica
SouthAmerica
Valid Certificates per Region [%]
% Certificates by Region
© 2017 - International Automotive Oversight Bureau 20 Slide courtesy of VDA QMC
Supplier Certification Progress
© 2017 - International Automotive Oversight Bureau
IATF 16949 - Progress
• As of 31st August 2017: 3,172 completed audits to IATF 16949
• As of 31st August, total NCs issued = 16,916 (average 5.33 ncs per audit)
© 2017 - International Automotive Oversight Bureau 22
Top 10 Major NCs – August 2017
• 7.2.3 Internal auditor competency
• 8.5.1.5 Total productive maintenance
• 6.1.2.3 Contingency plans • 10.2.1 (ISO) Nonconformity
and corrective action • 6.1.2.1 Risk analysis
• 10.2.3 Problem solving • 4.3.2 Customer-specific
requirements • 8.5.1 (ISO) Control of
production and service provision
• 4.4.1.2 Product safety • 9.3.2.1 Management
© 2017 - International Automotive Oversight Bureau 23
Top 10 minor NCs – August 2017
• 8.5.1.5 Total productive maintenance
• 8.5.1.1 Control plan • 8.5.1 (ISO) Control of
production and service provision
• 6.1.2.3 Contingency plans • 8.3.5.2 Manufacturing design
• 8.3.3.3 Special characteristics • 8.5.1.2 Standardised work –
operator instructions and visual standards
• 7.1.5.1.1 Measurement systems analysis
• 8.5.1.3 Verification of job set-ups
© 2017 - International Automotive Oversight Bureau
Actions to Ensure Success …
• Global Oversight Conducting monthly reviews with all 43 contracted certification bodies to ensure:
– CBs/Clients are scheduling transition audits – CBs have the necessary resources (auditors) – Forecasting audit schedule / auditor resources – Contingency plans where either timing or resources
cannot be achieved 24
© 2017 - International Automotive Oversight Bureau
Actions to Ensure Success …
• IATF Members Conducted Stakeholder Feedback session in Oberursel, Germany (near Frankfurt) 13th Sept. 2017
– All IATF contracted CBs were represented – Selection of certified suppliers represented – All Oversight Offices supported – All IATF OEMs and IATF National Associations supported
25
© 2017 - International Automotive Oversight Bureau 26
Subscribe to the IATF website…
© 2017 - International Automotive Oversight Bureau
Common questions … • Must we use both ISO 9001:2015 and IATF
16949:2016 when conducting audits?
• ANSWER: Yes, as it states in the IATF 16949 Foreword – Automotive QMS Standard, IATF 16949 is not a stand-alone standard, it must be used in conjunction with ISO 9001:2015
© 2017 - International Automotive Oversight Bureau
Common questions … • Will the IATF be granting waivers for those
organizations who cannot meet the Transition Plan timing?
• ANSWER: No, from 1st October 2017 onward, all audits are required to be conducted to IATF 16949
• There are no plans to approve/grant waivers • ISO/TS 16949 certificates are not valid past their
expiry or 14th September 2018, whichever occurs first.
© 2017 - International Automotive Oversight Bureau
Common questions … • What about competency for internal auditors and
second-party auditors? Do they have to all take an IATF-sanctioned lead auditor training course?
• ANSWER: No. Organizations are responsible for ensuring key personnel, including their auditors, are properly trained and competent. The IATF supports the use of IATF-recognized training providers; however, the IATF does NOT mandate the use of a lead auditor training course for all auditors in the organization.
• Organizations are still allowed to have key personnel trained and certified as lead auditors, and then using
© 2017 - International Automotive Oversight Bureau
Common questions … • What is the goal of 8.4.2.3? Do all organizations
supplying automotive product have to be IATF 16949 certified?
• ANSWER: As stated in 8.4.2.3, the ultimate objective is to have IATF 16949 certification; however, the IATF recognizes that for various reasons, that is not feasible for all organizations.
• At a minimum, the expectation is for organizations to be certified to ISO 9001:2015, unless otherwise authorized by the organization’s customer(s)
© 2017 - International Automotive Oversight Bureau
Common questions … • Do all of my support locations need to be audited to
IATF 16949 before the mfg locations can transition to IATF 16949?
• ANSWER: No. Please see the IATF 16949 Transition Strategy document. The Transition Strategy supplements Rules 5th Edition (and any SIs or FAQs related to Rules):
http://www.iatfglobaloversight.org/iatf-169492016/iatf-16949201-iatf-transition-strategy/
© 2017 - International Automotive Oversight Bureau
Next steps … • You need to have these critical things
• ISO 9001:2015 • IATF 16949:2016 • Rules 5 • Transition Strategy • Applicable CSRs
For the Standards and Rules, please see: www.aiag.org
© 2017 - International Automotive Oversight Bureau
Thank You!
IATF Transition Case Study – Stadco Ltd Mike Khanna and Matt Gill, Magna International
Stadco History
1812
Stadco History
John Hall
1812
Stadco History
Stadco History
Stadco Locations
16949
16949
16949
16949
Stadco Intranet Based Quality System
Timeline
Telford Plant Audit
Castle Bromwich Plant Audit
Powys Plant Audit
Shrewsbury Plant Audit
Documentation updates
Group Function Audit
Read & Gap Analysis
Training
Oct 1st 2016 Jan ‘17 Today Jan ‘18
Deadline Sept 14th 2018
Transition Steps Taken
• Group Senior Management Engagement
• Group role assigned as primary lead
• Plant stakeholder engagement
• Outline overall timing to include; – Group – Plants – 3rd parties; Training, CB, Suppliers
Transition Steps Taken
• Gather data – access to resources – AIAG, IATF, SMMT, Magna, BSi
• Select project tools – Plexus Gap Analysis Spreadsheet ; c.196 unique line items to be answered
inc. Annexes – Action Tracker Subdivided ownerships
• Determine responsibility split for Group & Plant – Address group tasks with group functional leads – Head Office audited 1st – Prepare interpretation for Plant leads – Standardise best practice
• Use our 1st Plant as the Pilot and test our approach & refine
Transition Steps Taken
Plant Approach Details
• Issue Group Gap Analysis findings and verify the potential Plant gaps
• Allow Plant the time to digest the combined analysis findings and interpretations
• Return & agree action plan with Plant Management team – Set priorities, factor in system updates and evidence of process taking
place
• Agree timing to meet deadlines, inc. readiness review
Plant Approach Details
• Set cadence & fix in diaries – Increasing in frequency towards the deadline
• Monthly, Fortnightly, Weekly
• Meeting style – Action review inc. escalation – Interpretation review – Readiness preparation
• Carry out IATF Audits
Trip Hazards
Trip Hazards
Requirement Potential Gap What we did
Increased management of suppliers
Enhanced audit framework inc. competence, scorecards
Updated current procedure with increased risk assessment, lead auditor training and scorecards.
Contingency Plan Testing
Inadequate test approach
Schedule IATF ‘Desk Top role play’ and feedback into recovery plan.
Trip Hazards
Requirement Potential Gap What we did
Risk Management Lack of evidence that risk assessment is undertaken and reacted to.
Building on current foundation and integrated approach, clarified the risk tools used and their link to improvement plans.
Temporary Change Of Process
Not a coherent process.
Establish current response, define process, link to similar activities like; PFMEA, Primary & Secondary Controls, Rework & Repair, Shutdown Verification.
Trip Hazards
Requirement Potential Gap What we did
Repair & Rework Not a coherent process.
Work to OEM R&R method as default. Create centralised best practice log to define process and approval.
Shutdown Verification
Not common across group.
Establish best practice from OEM’s and apply risk based logic at all plants.
The Audits
OK
Minor
Major
Audit
The Audits
Readiness Audit
• Focused on the changes to a fixed Certification Body checklist. – Supply advanced data – Prove you meet all requirements, > Checklist; Gap Analysis – Are we ready?
The Audits
Transition audit
• Office based elements were more IATF change orientated
• Production area elements were more familiar in focus
The Result
Key Recommendations
TRAIN EARLY
Key Recommendations
ENGAGE LEADERSHIP
Key Recommendations
START NOW!!
Questions please……