TS User’s Group - EAGLE Certification Group User’s Group TS 16949:2009 User’s 07/20/2010 ... June 2-4 IAOB Certification Body Training points Supplier Scorecard reviews Chrysler

© EAGLE Registrations Inc. 2010 CONFIDENTIAL 1

TS User’s Group

TS 16949:2009 User’s

07/20/2010

2© EAGLE Registrations Inc. 2010 CONFIDENTIAL

AGENDA

Updates to IAOB Management Group

TS 16949:2009 Transition

TS Rules 3rd/2009 Edition SI’s and FAQs

June 2-4 IAOB Certification Body Training points

Supplier Scorecard reviews

Chrysler CSR updates

MSA 4th Edition

Resources


Tripp Martin is currently Managing Director

Effective 16 September 2009

Mr. Martin will retain this position until further notice

Updates to IAOB Management Group


TS 16949: 2009 Transition

As of Oct 15, 2009 the IAOB has made it mandatory that all TS audits are performed to the 2009 revision

Your auditor will use the 2009 Upgrade Checklist to verify your compliance. Any areas that are not conforming will have an NCR issued and require a CA Plan and Objective Evidence of closure

Remember, this revision is to capture the updates to ISO 9001:2008.


No new 2009 edition Sanctioned Interpretations or FAQs have been released since last Users Group.

SI’s 6, 7, 8 and 9 issued February 2010

SI’s 10 & 11 issued April 2010

TS Rules 3rd and 2009 Edition SI’s and FAQs


SI 6- 2.2 IATF Contractual RequirementsThe certification body shall cooperate with the relevant IATF Oversight office in performing

activities in support of the IATF Certification Scheme.

SI 7- 2.3 Ongoing Recognition RequirementsStates that the IAOB will audit the CB according it’s Key Processes and Operating Procedures,

along with the other already identified audit material.

SI 8- 2.1 IATF Certification Body Recognition Requirements

States that a CB must be compliant with Regulations of each country in which it operates.



SI 9- 5.11 Nonconformity ManagementClarifies that the 90 days for closure of NCRs is understood to mean 90 calendar days

SI 10- 5.6 Audit TeamAdds language to clarify that the audit team (between them) shall have relevant sector specific

experience for all commodity codes which apply to that site.

SI 11- 7.0 Transfer AuditClarifies that Transfer Audits are to be equivalent to the time of a Recertification Audit and also

that the planning and conduct shall comply with 6.9 Recertification Activities.



June 2-4 IAOB CB Training

The FOCUS of the Training


Common understanding of requirements

Effective implementation of CB processes to meet the requirements

Any TS audit, by any recognized CB, using any certified auditor, anywhere in the world, yields the same result

Consistent acceptable product supplied to the OEMs

Scheme Goals….



This is the current edition

At this time there is no requirement or plan to move from a “TS” to an “IS”

Next revision that would be considered would be after ISO 9001:2008 is revised

TS 16949:2009 STATUS



WA Top 10 Areas

The Scheme is 10 years old now, what issues are being found?



Site Extensions are being misused

The intent is not to allow 2 entities that qualify as sites to reduce cost and audit days

The intent is to allow a TS certificate to address a manufacturing department of the organization that has moved close by the site due to space constraints

Site vs Site Extension



MfgDept.

Non-MfgDept.

ManufacturingSite

SiteExtension

MfgDept.

Non-MfgDept.

ManufacturingSite

Site vs Site Extension



“manufacturing department”

If it is not manufacturing, it is a remote, supporting function

Functions under the site’sManagementQuality Management System

Feeds its output back into the site’s manufacturing process


Site Extensions


“close by”

This had previously been defined as 5 miles. While this limit has been removed, the concept remains the same

If it is too far away, it is either a separate site, or it can be considered as a supplier


Site Extensions


Communiqué 2008-002

– If the proposed extension to a facility meets all the applicable ISO/TS 16949:2002 requirements without support from its original site, then the proposed extension or facility is considered a separate single site and [is] not eligible as a site extension


Site Extensions


Campus” Example

– Proximity of sites does not count as 1 Site with site extensions


Site Extensions


What is EAGLE doing to manage this?EAGLE will conduct a review of each site and will write a justification for any sites that qualify as site extensions.

What if your sites do not qualify as extensions? EAGLE will work with you and assess what the options are for your specific situation.


Site Extensions


Audits to multiple schemes

TS, ISO, EMS, etc. may be combined

The audit days for TS shall be independently calculated

The TS audit days must be able to be distinguished on the site audit plan/agenda

5.2 Audit Day Determination



e. All shifts

This means all shifts at the site for each auditManufacturing or non-manufacturingAny activity that is part of the TS quality management system

MaintenanceCalibrationClericalCycle countingStock rotation

Multiple shift patterns must be audited1, 2, 3, A, B, C, etc.




h. Ring fencing – “dedicated to automotive and completely separated in terms of ‘employee activity’”

If any manufacturing is shared, then NO

– It is not “completely separated”




Truncating or Rounding Down is not acceptable

– X.01 to X.09 X.0

– The result shall be rounded up to X.5• Example: 2.01 shall be rounded up to 2.5• Example: 2.49 shall be rounded up to 2.5

Rounding/Truncating of Audit Days



What if you’ve done it wrong?

1.Correction:

Find all clients where the initial, recertification or transfer audit occurred in 2010 and check the audit day calculation

If it was wrong, recalculate it properly

Add any missing audit day from the Stage 2/Recert/ Transfer audit to the next surveillance audit

Adjust the surveillance audit days such that the total surveillance audit days are correct

Rounding/Truncating of Audit Days



IATF is serious about a “fresh eyes” look at the client’s QMS every three years

Went from a “should” (Rules 2) to a “shall”because of abuse

Auditor Rotation is REQUIRED.

No Waivers approved

5.6 Audit Team



Second Largest Amount of Witness Audit Findings

Basic issues:

Not planning the audit based upon the client’s processes

Not prioritizing the audit based upon OEM concerns and client internal audit concerns

Not auditing of interactions of client processes

5.7 Audit Planning



First Largest Amount of Witness Audit Findings

questioning the process objectives/ targets, with a focus on targets not being met….

Failing to question the auditees on performance to objectives for the each of the client’s processes examined

Not prioritizing audit trails for the objectives not being met

5.8 Process Approach



Clients words

Directly relate back to the client’s Key Process Map

Do you have measurables for each of these?

Is it clear?



All issued nonconformances (majors and minors) initiate the client decertification process (see 8.1)

The CB procedure should define when suspension is considered

CBs are accepting poor correction, poor root cause analysis, and poor corrective action

5.11 Nonconformity Management



The 90 days is for closure of the client nonconformity (including on-site verification of a major) SI-9

If when you go to verify, the corrective action is not in place?

Minor to Major

Major to Suspension

Suspension to Withdrawal

5.11 Nonconformity Management



Scorecard Review-GM


Scorecard Review-GM

Six Panel - Defined:

– A 6 Panel contains trend charts for 6 Measurables(GM Global Quality Tracking System)

• PRRs (Problem Reporting and Resolution)• PPM (Parts per Million)• Discrepant Parts• Spill• Stockout• Downtime

(See GP-5 for definitions of each)

– Charts are updated once per week (available by Tuesday afternoon)


How Suppliers Access 6 Panel

1. Log into GM Supply Power

2. Under the ‘Applications’channel choose ‘Quality Reports’

3. You will see the 6 Panels to which you have access

Scorecard Review-GM


=W30

100% Deterioration CYTD

100% Improvement


DUNS: 123456789, WHOVILLECommodity: M SAMPLE SIX INC

Executive Champion: XXSQE: YY

SQ Contact: ZZ

Monthly



Report Name: Supplier Activity / ChartsBlue line current 12 months (Diamonds)

Green line prior 12 months (Squares) Data As Of Jun 2 2010

100% Improvement

PR/R's4

3

0

3 3 3

0

2

1

4

2

3

2

3 3

4

2

1 1 1

0

4

00112233445

Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10

Discrepant Parts

6 2 0

30

54

130 3 0

39

92

7

101

0

21

215

3 2 4 0 0

27

00

20

40

60

80

100

120

Jun-090 Jul-09 Aug-090Sep-09 Oct-09 Nov-09 Dec-09 Jan10 Feb-10 Mar-10 Apr-10 May-10

PPM's

10 5 0

47

83

250 6 0

63

200

16

164

0

303

185 4 5 0 0

46

00

50

100

150

200

250


Stockouts

0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 0

1

00

0

0

1

1

1

1


Spills

0 0 0 0 0 0 0 0

1

0 0 00 0 0 0 0 0 0 0 0 0 00

0

0

1

1

1

1


Downtimes

0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 0 0

1

0

0

0

1

1

1

1


Scorecard Review-GM


Every direct supplier of production parts to GM has a 6 Panel scorecard (Ultimate duns and all mfg duns)

As part of the audit planning and site audit, review the 6 panel information

Supplier refusal to disclose, or claiming ignorance? Major NC should be issued – see TS 8.2.1 and 8.2.1.1

Review trends of performance in 6 Panel

Establish audit trails based on metric patterns indicating deterioration or anomalies

Scorecard Review-GM


Internal Audit – 8.2.2.2 mfg process audit

– Organization shall audit to determine effectiveness

– Process audits in GM Customer Specifics:• Heat Treat (CQI-9) – 4.1.12• Plating (CQI-11) – 4.1.13• Coating (CQI-12) – 4.1.14• GM Process Audits – 4.1.xx (to be added)• GM Commodity Audits – 4.1.xx (to be added)

GM Process Audits

Scorecard Review-GM


Scorecard Review-Chrysler



Basic Information

Division / Company Roll-up

Company Results

Manufacturing Location Results

External Balanced Scorecard (EBSC)



New Score Card - Status Indicators

Not performance measures

Report on either corporate or location compliance to requirements

Do not impact score but do reflect Partnership mindset



May– EBSCs will be found in GPSIS Portal– Informational data only– Hands-on review by Chrysler and Suppliers– Content / value check

June– 45 D.I.S. Workshop

July– EBSC fully live in GPSIS

Timing, Next Steps



Quality

NCT rates– High NCT rates are indicative of something wrong in

the supplier’s quality system.– Significant NCT rates

Warranty

Containments (Yard Holds, # of occurrences)

Forever Requirements violations

Product Development Process (AQP)

Using Scorecard Metrics to Prioritize the Audit



All Chrysler suppliers are required to have access through Covisint.

– Chrysler Applications Section – EBSC

A Major Nonconformance will the supplier cannot access the system.



Go to:http://www.covisint.com/loginAuto.shtml

1. Enter user ID2. Enter password3. Click Submit

3CPR WBS access requires Covisint. Company Covisint Administrator can provide a user login

1

2

3


1

2

1. Click on the Chrysler Portal2. If this link is missing, contact the Company Covisint Administrator





CUSTOMER-SPECIFIC REQUIREMENTS

Editorial updates/corrections

Document has been restructured to follow TS 16949

User-friendly features added– “Table of Contents”– Expanded “References” section– ISO/TS 16949 references & cross-reference summary– Comprehensive “Change Log” (2007/2008 changes

included)

Significant deletions and additions

Chrysler-CSR update


DELETIONS

“Chrysler-approved laboratories” requirement

“Elements of Manufacturing Basics” audit

“SQAP” exceptions


Chrysler-CSR Update


ADDITIONS

4.2.1 ISO/TS 16949 Registration Verification

5.0 Environmental Management (ISO 14001) required

4.11 Customer Satisfaction-Needs Improvement Notice

4.10 Consumer-Centric Warranty Management


Chrysler-CSR Update


Customer Satisfaction - Needs Improvement Notice

Supplier candidates identified by metrics-driven internal process

Notifications sent to Certification Body & Oversight Office

Process follows “Certificate Decertification Process” outlined in the 3rd Edition of the Certification Scheme

4.11 New Special Status Condition

Chrysler CSR Update


CQI 14

CQI-14 assessment tool column headings

2nd Edition

Consumer Centric Warranty Management


CQI 14 Scoring

Each section sums up the score for the section and then divides by the number of questions to obtain a score for the phase.

Phase scores are then automatically transferred to the scoring summary located on the Scoring tab in the tool

Note: For corporate facilities with multiple manufacturing sites, the corporate scoring for manufacturing questions should reflect the lowest single manufacturing site's score.


MSA Reference Manual

MSA Reference Manual – What Changed?The Measurement System Analysis (MSA) third edition reference manual has been updated. Key changes include the addition of examples to aid in the understanding of basic measure system fundamentals. Further enhancements include:

Improvements to the table of contents to aid in the manual usage

Clarification of the relationship between calibration and MSA

Clearer definition of the measurement decision (5-10-30)

Improved the bias and linearity sections

Clarified and improved the attribute and the non-replicable (i.e., destructive) testing section


What:MSA Update and WorkshopWhen: August 19, 2010 Where: Schoolcraft College/VistaTech Center, Livonia, MI 48152 Register: Online or call (248) 358-3003 Overview on Changes to MSA – Calibration and relationship to external systems; e.g., ISO 17025 – Repeatability analysis with bias/linearity studies – Discussion of risks; alpha, beta – GRR analysis with respect to target Cp – nda definition – Attribute updates APQP and MSA – Systems approach – Measurement source development Examples of advanced MSA – Destructive – Test Stands – MSA and True Position Analysis Workshop – Attribute: hands-on data collection – Variable – Replicable: hands on data collection – Nonreplicable: Evaluation of different reports

The registration fee for AIAG members is $99; the non-member fee is $199. All attendees will receive a complimentary copy of the Measurement Systems Analysis, Forth Edition.

MSA Reference Manual


Resources

www.customerspecifics.com

Database of Customer Specifics

Development phase

Community – Access– Share– Discuss


www.iatfglobaloversight.org

Provides the latest on

•Customer Specific Requirements

•SI’s and FAQ’s for the Standard and Rules

•OEM Communiqués

Resources


www.aiag.org

Access to purchase CQI’s mentioned in presentation

AIAG provides access to publications and training, such as:

• TS Auditor courses

• TS Executive Understanding

• TS Internal Quality Auditing

• TS Supplier Auditor Certification

• ISO/TS 16949:2009 and lessons learned from the Process Approach

• Understanding ISO/TS 16949

Resources


Questions?


Thank you for attending!!

A copy of the Power Point will be sent out next week.

Contact: [email protected]

1.800.795.3641

Documents

TS User’s Group - EAGLE Certification Group User’s Group TS 16949:2009 User’s 07/20/2010 ... June 2-4 IAOB Certification Body Training points Supplier Scorecard reviews Chrysler