IATF 16949

Ford Motor Company

 Requirement to Certify to IATF 16949

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

Copyright © 2017 Ford Motor Company

 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
Copyright © 2017 Ford Motor Company
 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
Copyright © 2017 Ford Motor Company
 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

Copyright © 2017 Ford Motor Company

 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

Copyright © 2017 Ford Motor Company

 Transition to IATF 16949 - Resources

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

Copyright © 2017 Ford Motor Company

 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
Copyright © 2017 Ford Motor Company
 Transition to IATF 16949 - Status

Questions?

Copyright © 2017 Ford Motor Company

Aaron A. Dodak
Global Supplier Quality Manager
General Motors – Supplier Data

Top 10 QMS Failures (BIQS Elements)

General Motors

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.
Intervention Workshop

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

The Core Focus of the 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.
General Motors

What Can Be Accomplished

by Creating a Successful
Partnership with Safety and
Quality as the Primary Focus?
 AIAG Quality Summit

IATF 16949:2016 Update

Automotive QMS Transition
September 19, 2017

Ms. Cherie Reiche, IAOB

© 2017 - International Automotive Oversight Bureau
 % Certificates by Region
Valid Certificates per Region [%]

68.2%

0.8%

2.2%

9.2%

2.6%
17.0%

Africa Asia Europe Middle North South

Pacific East America America

© 2017 - International Automotive Oversight Bureau 19

 Supplier Certification Progress

© 2017 - International Automotive Oversight Bureau Slide courtesy of VDA QMC 20

 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

 Top 10 Major NCs – August 2017

• 7.2.3 Internal auditor • 10.2.3 Problem solving

competency • 4.3.2 Customer-specific
• 8.5.1.5 Total productive requirements
maintenance • 8.5.1 (ISO) Control of
• 6.1.2.3 Contingency plans production and service
• 10.2.1 (ISO) Nonconformity provision
and corrective action
© 2017 - International Automotive Oversight Bureau
• 4.4.1.2 Product safety 22
 Top 10 minor NCs – August 2017

• 8.5.1.5 Total productive • 8.3.3.3 Special characteristics

maintenance • 8.5.1.2 Standardised work –
• 8.5.1.1 Control plan operator instructions and visual
• 8.5.1 (ISO) Control of standards
production and service • 7.1.5.1.1 Measurement systems
provision analysis
•© 20176.1.2.3 Contingency plans
- International Automotive Oversight Bureau
• 8.5.1.3 Verification of job set-
23
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
© 2017cannot be achieved
- International Automotive Oversight Bureau 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
© 2017 - International Automotive Oversight Bureau 25
Subscribe to the IATF website…

© 2017 - International Automotive Oversight Bureau 26

 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
© 2017 - International Automotive Oversight Bureau
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
© 2017 - International Automotive Oversight Bureau
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/
© 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!

© 2017 - International Automotive Oversight Bureau

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

1812
Stadco History

1812

John Hall
Stadco History
Stadco History
Stadco
Locations

16949

16949

16949

16949
Stadco Intranet Based Quality System
 Timeline
Oct 1st 2016 Jan ‘17 Today Jan ‘18

Read & Gap Analysis

Deadline
Sept 14th 2018
Documentation updates

Training

Group Function
Audit

Castle Bromwich
Plant Audit
Powys Plant
Audit
Shrewsbury
Plant Audit

Telford Plant
Audit
 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 Enhanced audit Updated current procedure with increased risk
management of framework inc. assessment, lead auditor training and
suppliers competence, scorecards.
scorecards

Contingency Plan Inadequate test Schedule IATF ‘Desk Top role play’ and
Testing approach feedback into recovery plan.
 Trip Hazards

Requirement Potential Gap What we did

Risk Management Lack of evidence Building on current foundation and integrated
that risk approach, clarified the risk tools used and their link
assessment is to improvement plans.
undertaken and
reacted to.

Temporary Not a coherent Establish current response, define process, link to

Change Of process. similar activities like; PFMEA, Primary & Secondary
Process Controls, Rework & Repair, Shutdown Verification.
 Trip Hazards

Requirement Potential Gap What we did

Repair & Rework Not a coherent Work to OEM R&R method as default.
process. Create centralised best practice log to define
process and approval.

Shutdown Not common Establish best practice from OEM’s and apply risk
Verification across group. based logic at all plants.
The Audits

OK

Audit Minor

Major
 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……