IATF 16949 Ford Motor Companyadmin.aiag.org/docs/uploads/events/presentations/S17QUALITY/IATF... · suppliers are ISO/TS 16949 or IATF 16949 compliant. Yet, non-conforming errors

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


• 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


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


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


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


Go to the IATF web site for the latest news, interpretations and updates

Transition to IATF 16949 - Status


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


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


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)


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


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


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


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


Subscribe to the IATF website…


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


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.


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


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)


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/


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


Thank You!

IATF Transition Case Study – Stadco Ltd Mike Khanna and Matt Gill, Magna International

Presenter

Presentation Notes

Presenter – MK Good morning etc. etc. To help us pitch this right, please could I get a show of hands ‘Who here has already been through an IATF audit?’, ‘hands up who believes they have a good plan to get their company through it’s audits within the official timeframe?’, don’t worry, I won’t ask the rest of you to put your hands up So myself and Matt are going to tell you our story that ends with one of our plants achieving IATF certification (I believe we were 28th of 68,500 worldwide) Hopefully this will help you in your own planning, and maybe you can learn from some of our mistakes along the way. I’ll start be giving you a quick overview of the history of Stadco and our Quality systems, I’ll then hand over to Matt who will talk you through some of the detail of what we experienced and we will finish with our key recommendations. There’ll be time for questions at the end, so if you could hold them until then, that would be great. *

Stadco History

1812

Presenter

Presentation Notes

Presenter – MK So our story starts 205 years ago in 1812, this is the time of the Napoleonic wars *

Stadco History

John Hall

1812

Presenter

Presentation Notes

Presenter – MK and the middle of the Industrial Revolution when a man by the name of John Hall started a business in Liverpool dealing in iron. and we’re able to trace the history of Stadco all the way back to John. *

Stadco History

Presenter

Presentation Notes

Presenter – MK In fact, the company was known as Hall Engineering up to as recently as 1999 and we became part of the Magna family at the start of last year. In all that time our business had worked in the conversion of metal, and for the last 46 years, this has been in the supply of body panels to the motor industry. *

Stadco History

Presenter

Presentation Notes

Presenter – MK starting with the Ford Cortina MK3 in 1971. *

Stadco Locations

16949

16949

16949

16949

Presenter

Presentation Notes

Presenter – MK We have four manufacturing sites in the UK, all in the Birmingham area, * and each site had it’s own TS certificate. * Our head office support functions are based at one of the sites, but are audited separately and referenced in each sites certificate. * Our Certification body is BSI * and we are not design responsible.

Stadco Intranet Based Quality System

Presenter

Presentation Notes

Presenter – MK We have a centralised Business Management system hosted on our Intranet that we developed in the run up to TS certification in 2003. * It covers all of our business processes, from strategy deployment, * through top level process maps and * procedures right down to * forms and work instructions on the shop floor and it incorporates all of the requirements for our Quality, Health and Safety and Environmental accreditations. But more than that, it’s where people go if they want to know how to do something, IT’S ALIVE! *

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

Presenter

Presentation Notes

Presenter – MK * Our activities began in earnest last October with the issue of the new standard. * On that day, we started our gap analysis and in parallel * started our documentation updates. * We would have liked to have started our training activities earlier (in particular our auditor training), however it wasn’t until the early part of this year that there were providers available to give us what we wanted. As each of our sites reference our head office activities, * it was this that had to be audited first followed by the * audit and accreditation of our first plant in Castle Bromwich. * Through the remainder of this year, we will complete the audits of each of our remaining plants and we plan to have the whole company accredited by February/March next year. I will now hand you over to Matt who will take you through some of the details of what we experienced. *

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

Presenter

Presentation Notes

Presenter – MG * We compiled and Executive Brief to secure Senior Management Team engagement * In my group role I was assigned as primary lead and could dedicate the time needed * I met with all the plant teams to secure further engagement * Following these steps I could create the overall timing plan and ensure all interested parties were included *


• 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

Presenter

Presentation Notes

Presenter – MG * I was able to gather data from various sources, getting both global and local perspectives * From these resources I selected the right tools for the job ahead * As Mike mentioned we have a Corporate Certificate and through the Gap Analysis I determined the split between Group & Plants * * * ‘The train was already rolling, we just have to keep it on the track!’


Presenter

Presentation Notes

No note.

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

Presenter

Presentation Notes

Presenter – MG * Using the Plexus Gap Analysis Tool we shared the initial findings & completed the analysis across the Plants. With a lot to take in this was useful to filter in to the Green, Yellow and Red allowing us to prioritise* With the agreed reds & yellows in place a necessary period of ‘digestion’ was allowed for the Plant * before returning with the goal of setting a plant specific detailed action plan, not forgetting the readiness review needing to be factored in to the timing.*

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

Presenter

Presentation Notes

Presenter – MG * Follow up meetings took place and rigorously timed to meet fixed audit dates * ‘Surgery’ style of meeting was used to add value to participants workstreams * Internal audits took place to ensure compliance *

Trip Hazards

Presenter

Presentation Notes

Presenter – MG * I’ll take you through some of the things to look out for based on our experience *

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.

Presenter

Presentation Notes

Presenter – MG Updated current procedure with; Risk assessment element to determine which type of audit to use to a transparent criteria, formally trained staff to lead auditor level & adjusted scorecards * Schedule non-EHS tests through ‘Desk Top role play’, feedback any issues or discrepancies to recovery plan *

Trip Hazards


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.

Presenter

Presentation Notes

Presenter – MG Building on current foundation; Strategic Planning, PFMEA & EHS. Showing our integrated approach. Clarifying the ‘Risk’ tools & methods used. Proving outcomes form part of improvement / development strategy & plans * Establish current response, define process, link to similar activities like; PFMEA, Primary & Secondary Controls, Rework & Repair, Shutdown Verification *

Trip Hazards


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.

Presenter

Presentation Notes

Presenter – MG Work to OEM method as default, centralise current best practices, define process; access, updates etc. Approve the documented R&R methods. * Establish best practice, apply risk based logic, define acceptable process; default OEM requirement. Roll out minimum Stadco requirements.

The Audits

OK

Minor

Major

Audit

Presenter

Presentation Notes

Presenter – MG So having done all the hard work it was time for the audits, as mentioned Group were 1st and give assurances the common detail was in place *

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?

Presenter

Presentation Notes

Presenter – MG The plant readiness review was the road test of all our hard work, essentially ending with a decision of ‘are we ready?’

The Audits

Transition audit

• Office based elements were more IATF change orientated

• Production area elements were more familiar in focus

Presenter

Presentation Notes

Presenter – MG Both the Group Office and the Plant Office based elements were more IATF orientated * Production area elements were more familiar in focus *

The Result

Presenter

Presentation Notes

Presenter MG We received no Majors throughout any of the audits to date, so following submission of the evidence packs to assure NCR closure we received confirmation of our 1st plant’s certification award on May 19th 2017. * I will now hand back to Mike.

Key Recommendations

TRAIN EARLY

Presenter

Presentation Notes

Presenter – MK So in summary, our key recommendations are: * Train early – ensure the people who are going to have to implement the changes know why. A particular focus is needed on your internal and Supplier Auditors.

Key Recommendations

ENGAGE LEADERSHIP

Presenter

Presentation Notes

Presenter – MK * Engage your Leadership teams: Not a new concept I know, but we truly wouldn’t have achieved what we did without their backing.

Key Recommendations

START NOW!!

Presenter

Presentation Notes

Presenter – MK and if like us, you want to be around in another 200 years *, START NOW!

Questions please……

Presenter

Presentation Notes

Presenter – MK OK ‘who’s got the first question then?’

Documents

IATF 16949 Ford Motor Companyadmin.aiag.org/docs/uploads/events/presentations/S17QUALITY/IATF... · suppliers are ISO/TS 16949 or IATF 16949 compliant. Yet, non-conforming errors