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ISO/TS 16949:2002

Expiration of QS-9000

ISO (Geneva, Switzerland) has stated that


QS-9000 has been extended by 3 years,
and will expire on 14 December, 2006
ISO has indicated that there is virtually no
chance of additional extensions,
nominally, the ISO 9000:1994 standard
embedded within QS-9000 will expire 15
December, 2003.
Two Key Organizations

International Automotive Task Force

International Automotive Oversight Bureau


Purpose of the IATF

Develop consensus for international quality


system requirements (automotive)
Develop policy & procedure for registration
Provide appropriate training
Serve as formal liaison
IATF Members

Authoring Organization of ISO/TS 16949 includes:


Vehicle manufacturers: BMW, DaimlerChrysler, FIAT, Ford
Motor, GM, PSA, Renault, Volkswagen
Industry trade organizations: AIAG, ANFIA, FIEV, SMMT,
VDA
Guest members: JAMA
IATF Oversight

ANFIA, IAOB, IATF-France, SMMT, VDA-QMC


Implementation of IATF registration scheme and rules via
a common process
Witness audits
Auditor qualification training and exam

Monitor CB/auditor performance

Apply and implement IATF policy and decisions


Coordinate special projects and work teams
Develop sanctioned interpretations and recommendations
for improvement
Database management
Purpose of IAOB

Implement and manage 16949 registrations


Manage and coordinate with IATF Europe
Support further global consistency
Develop and maintain central database
Which Car Manufacturers Will
Accept ISO / TS 16949?
The users of -
QS-9000 - US Big 3
VDA 6.1 - German
AVSQ - Italian
EAQF - French
Why Upgrade to TS?

From the OEM subscribers view:


TS 2nd is based on the current ISO 9001:2000
Includes Customer Specifics to achieve
conformity
Improved control of the auditing process
Reduced audit variation
Better control of certification and its value
Why Upgrade to TS?

From the suppliers point of view:


Reciprocal recognition (one size fits all)
Vocabulary is consistent with ISO 9001:2000
Process audit is aligned with the way the automotive
business is run
Continual improvement from earlier requirements
documents (e.g., TS 1st, QS-9000, EAQF, AVSQ, VDA
6.1)
Closer oversight greater value in certification
ISO/TS 16949:2002 Addresses
Significant QS-9000 issues
The Oversight process
- Tighter registrar control than with QS-9000 Accreditation Body
method, and higher quality auditors
International recognition of ISO/TS 16949:2002
- The Multinational OEM authoring group reduces the number of
certification requirements in Europe, and therefore cost

ISO/TS 16949:2002 is based on and includes ISO 9001:2000


- ISO 9001:2000 includes strengthened management reporting,
continuous improvement and customer satisfaction metrics
(aligned with Q1 2002)
Eight Principles
Customer focus
Leadership
Involvement of people
Process approach
System approach to management
Continual Improvement
Factual approach to decision making
Mutually beneficial supplier relationships
Introduction

The goal of this Technical Specification:


development of a quality management system
provide for continuous improvement
emphasize defect prevention
reduction of variation and waste in the supply
chain
Through industry standards -
ISO9001:2000 & ISO/TS16949:2002.

The intent of this international standard is to


encourage the adoption of the process approach to
manage an organization.

Process approach - for organizations to function


effectively, they have to identify and manage
numerous interrelated and interacting processes.
The systematic identification and management of
the processes employed within an organization and
particularly between such processes is referred to as
process management.
How Will the Audit Change?
Process audit approach
Automotive application
Line of sight from the organization to the customer
Audit plan
Identification of key processes impacting the customer
Based on the processes as defined by the organization
Performance
Linked to common metrics for
Organization
Supplier

Oversight
Adherence to the Rules and Common Global Process
Continual Improvement Cycle
Management
R Responsibility S
C E C A
U Q U T
S U S I
T I Resource Measurement, T S
O R Management Analysis O F
E C.I. A
M M
M
& Improvement C
E E
R E R T
N I
T O
S N
Inputs Product Outputs
Product
Realization
ISO / TS 16949

Scope and Applicability


Applicable to production and service part
supplier sites that are providing:
Parts or materials
Heat treating, painting, plating, other finishing services
Other customer specific products
May also be applied throughout supply chain
Whats New (and Different)

Based on ISO 9001:2000 not ISO 9001:1994


Greater focus on the customer and customer
satisfaction
New focus on the Process approach vs. the
elemental approach
Clarification of requirements for continual
improvement
New and Different (Cont.)

Greater emphasis upon the role of top


management
Measurable quality objectives
Reduced emphasis on documented
procedures
New and Diff. (Cont.)

Modification in the purpose of internal audits


Use the Deming Cycle of Plan, Do, Check,
and Act as a basic methodology
Process Conrol and improvement is
expanded from product to include all
activities of the organization.
ISO 9001 Supply Chain Terms

S U P P L IE R Was
Subcontractor
in QS-9000

Was
O r g a n iz a tio n Supplier in
QS-9000

C u s to m e r
Automotive Specific
Terminology
Adds sector terminology Modifies ISO terms
Control plan Continual improvement
Design responsible org. Manufacturing
Error proofing
Laboratory
Laboratory scope
Outsourcing
Predictive maintenance
Premium freight
Remote location & site
Special characteristics
ISO 9001 Core Sections
ISO / TS 16949
Permissible Exclusions

The only permitted exclusions may be in 7.3


Where the organization is not responsible for product design and
development
Permitted exclusions do NOT include manufacturing process
design
Justified with details in the quality manual
Conformity should not be claimed otherwise

Only IATF will prescribe authorized exclusions for


vehicle assembly plants
Mandatory Procedures

ISO 9001:2000 ISO/TS 16949:2002


Control of Documents Laboratory
Control of Records Field Service (i.e.
Internal Audit Warranty)
Control of Training
Nonconforming Product
Corrective Action
Preventive Action
Key Differences between
QS-9000 & TS16949
TS16949 focuses on the business processes required to
satisfy customer requirements (The Process Approach).

QS-9000 follows the 20 elements (The Conformity


Approach)

Process audit (TS16949) vs. documentation audit (QS-


9000)
Contrast between QS-9000 &
TS-16949:2002
QS-9000 TS-16949:2002
(Procedure Based) (Process Based)

Procedures Are: Processes Are:


Driven by task completion Driven by desired output
Issued Managed
May be completed by different May be completed by different
departments with different objectives departments with the same objectives
Are segmented Flow to conclusion
Satisfy the standard Satisfy the stakeholders
Define the sequence of steps to Transform inputs into outputs
perform a task Dynamic
Static
Management of Processes

1 2 3 4

als
go
Process 1 1

Process 2 2

s
es
Process 3 3

oc
Process 4 4

Pr A FUNCTIONAL
ORGANIZATION
WITH PROCESS
Functional Goals OVERLAYS
Recognizes:

All work is performed to achieve some objectives

The objective is achieved more efficiently when related resources


and activities are managed as a process

Objectives of the organization which serve to meet its mission


will be met more effectively when the organization is managed as
a system of interrelated processes.
The Process Approach

Purpose

Objectives Risks

Inputs Process Outputs


Stakeholder Wants & Needs
Products
Specifications
Information
Schedule/Timing
Market Data Results
Industry Trends
Economic Conditions
Process Mapping
Marshall Key Processes

Program Planning &


Manufacturing Shipping
Launch

Support Processes Business Processes

Manufacturing Information Document Corrective


LRP/OP CQR/CQA Component Quality Internal Auditing Preventive Action
Roadmap Management Control Action

Human Resource Non-conforming Materials


Asset Management Capacity Planning Purchasing
Management Material Management

Management
Review / Continuous
Supplier Improvement
DFM Customer Support Laboratory Records Retention 5S Audit
Management

Quality
Objectives

Supporting Instructions

Forms and Form Instructions


Process Mapping

How do I get started mapping????


First map out our processes at your location at

the macro level


Identify the process owner

Map out your processes at the micro level that

support the processes at the macro level


Process Mapping

You will need to identify


The inputs to your processes

The outputs of your processes

And then map out the activities in between that

define the processes


You might find sub processes

Identify metrics to measure the effectiveness

of your processes (must tie to the process


objective)
Process Mapping

Identify your customers and your process


objectives/outputs (TS16949 section 4.2.2.c)
Internal (other processes) and External

customers
Show interactions between the various

processes
Process Mapping

Identify your customers and your process outputs


(TS16949 section 4.2.2.c)
Physical products

Documents

Information

Services

Decisions

On time to schedule

Meet profit margins


Process Mapping
Identify suppliers to your process (internal and external)
(TS 16949 section 4.2.2.c)
What are their inputs to your process

Other processes

Labor

Material

Ideas

Information

Environment

Procedures, Forms, Documents, Records


Process Mapping
Identify support to your processes (TS16949 section
4.2.2.c)
Human Resources

Training

Purchasing

Finance

Quality Assurance

Etc.
Process Mapping

Establish a goal against which to measure your metrics


You will need to monitor your metrics and implement

corrective actions if you dont meet your goal


Look for opportunities of continual improvement to

improve your processes


Process Mapping

Identify risks to the process and the objectives


Compressed Timing
Failure to meet schedule timing
Incomplete customer requirements
Test/performance failures
Rejected approvals (appearance, PPAP)
Underestimated costs
Premium freight
Process Mapping

Flow chart the process.


Note:
Indicating forms/records to be filled out at each step of the
process can eliminate or reduce the need for procedures to
document activities at each step.
A well done flow chart can eliminate the need for a
procedure to describe the process.
Questions to Help with Mapping

Purpose Inputs/Suppliers
Why does this process exist?
Where does the information or
material you work on come
What is the purpose of this process?
from? Who are your suppliers?
What is the outcome? What do they supply?
Outputs Where do they affect the process
What product does this process make? flow?
What are the outputs of this process? What effect do they have on the
At what point does this process end? process and on the outcome?
Customers Process steps
Who uses the products from this
process? What happens to each input?
Who are the customers of this process? What conversion activities take
place?
Process Name / Level: Document No./ Release No.

Prototype Process - Farmington Hills (Level 2) 345643/ERD 2345


P ro cess Objective: P ro cess R isks: P ro cess M easurables: Suppo rt P ro cesses:

Build and deliver on-time, 1. M issed delivery date to the customer. 1. On-time delivery. Configuration M anagement
prototype parts that meet 2. Parts do not meet customer requirements in quality or performance. 2. Prototype rejections by the customer. M anufacturing
customer design &
ProgramM anagement
performance requirements.
Purchasing

Inputs P ro cess Outputs R ules/R espo nsibilities

(1) Receive (1) Sales Department.


Functionally Test
Customer Customer P.O.,
Prototypes
Order EDI, Phone, Fax, (2) Sales Department.
M ail
(3) Team usually can consists of Engineering, Quality, Sales,
ProgramM gt., M anufacturing.

(4) Sales Department.


(2) Enter order Test Y es
Issues ? (5) If parts are required, parts may be ordered by
into SAP System
Engineering, Sales or supplied internally froma TRW
(7) Resolve manufacturing facility.
with the
No (6) Prototypes built in accordance to build checklist,
Customer
drawings & specifications.

(3) Review Order (7) Engineering to coordinate deviation or customer


Requirements with concurrence.
Prototype Team (8) Quality
Inspection (8) Quality Assurance performs & documents inspections
using inspection standards or prototype control plans,
depending upon the specific customer requirements.

(9) Quality Assurance coordinates any required deviations


using the specific customer forms.
Order
No (10) Quality Assurance documents results using the specific
Issues ? Quality Y es
Y es Issues ? customer paperwork and maintains copies for future reference.
Paperwork may be sent with the prototype parts or forwarded
(9) Resolve to the customer via mail or fax depending upon specific
with the customer requirements.
(4) Resolve with No Customer
(11) Shipping Department packas parts and coordinates
Customer
develivery. Sales isrwponsbile for alerting shipping in advace
if expidated develiry will be require3d.

(10) Complete (12) Finance Department coordinates billing and collection.


Prototype
Prototype Sales Department may assist in overdue collection through
Revised Paperwork
Paperwork direct customer contact.
(5) Components
Y es P.O. No Inventory Check
Req'd?

(11) Packing & Prototype


Shipping Parts
Components

(6) Build (12) Issue


Drawings Customer
Prototypes Billing to
Invoice
Customer

Specifications
Process Nam: Back to Marshall Key Processes Document No. Revision

Marshall Shipping Process MPM0078 A


P rocess Objective: P rocess Risks: P rocess M easurables: Support P rocesses:

Ship quality product per 1. On-line system goes down and customer orders are missed. 1. On-time delivery performance report (internal). M aterial M anagement
customer requirements. 2. The wrong quantities are shipped. 2. On-time delevery performance report (external) Document Control
3. The shipment is not on time to the customer schedule. 3. P remium Freight. Non-Conforming M aterial
4. Customer not notified (no ASN) 4. Customer Quality
5. No invoice or not correct. 5. Finished Goods Inventory
6. Customer requirements not met. 6. Finished Goods Accuracy

Inputs P rocess Outputs R ules/R esponsibilities/C omments

1. Shipping A ssociate

Report and
Warehouse
M ove to
Storage
Finished Goods

Invoice
Customer

Assemble/Verify
Shipment

Pull Signal to
M anufacturing

Governing Documents

Ship Product
1. Shipping instructions.
2. Government R egulations
3. C ustomer R equirements
Process Nam: Back to Marshall Key Processes Document No. Revision

Assemble / Verify Shipment MPM0079 A


P rocess Objective: P rocess R isks: P rocess M easurables: Support P rocesses:

Ship quality product per 1. On-line system goes down and customer orders are missed. 1. On-time delivery performance report (internal). M aterials M anagement
customer requirements. 2. The wrong quantities are shipped. 2. On-time delevery performance report (external) Document Control
3. The shipment is not on time to the customer schedule. 3. P remium Freight. Non-Conforming M aterial
4. Customer not notified (no ASN) 4. Customer Quality
5. Dropped parts. 5. Finished Goods Inventory
6. Finished Goods Accuracy

Inputs P rocess Outputs R ules/R esponsibilities/C omments

Delivery Note
1. Shipping A ssociate
fromCustomer Review Pick List
2. Shipping C lerk
Service

Stored Finished Consult SAP


Goods inventory screen.

Reference on-hand inventory screen


when picking shipment

Is container
within the two Identify out of rotation or missing box
No
week window and forward to inventory analyst. (2)
of stock Warehouse
Nonconformance
Y es Governing Documents
Is all stock
available? No 1. C ustomer P ackaging Specifications
Y es Y es
2. Delivery Note
Contact 3. Honda Delta System
Y es
No
M anufacturing or 4. DC X SM A R T System
Customer Service 5. Ford DDL
Is the box
damaged or 6. M M OG
dropped? Is stock in
the correct No
quantity?

No
Y es

Pull Order
Is another box
required?

Assemble order
Shipment
per customer Place on truck
Configuration
directives
What About the AIAG
Reference Manuals?
The AIAG reference manuals (PPAP, FMEA,
MSA, APQP & SPC are still viable documents.

References to these manuals will be included in


DCX, Ford and GMs respective customer
specifics for TS16949.

Certification to TS16949 also includes the


requirements defined in the AIAG reference
manuals.
Questions?