Categories: Auditing ,  Automotive Industry

Auditing the Automotive Process Approach

Course Description
To be qualified to conduct ISO/TS 16949:2002 internal and supplier audits your
auditors must demonstrate a sound practical competency in both Quality management
system auditing and Manufacturing process auditing methodologies.

This comprehensive two-day course provides practical instruction and hands-on workshop
sessions to ensure that your auditors thoroughly understand the principles and practices involved.

Who Should Attend?
Quality professionals with experience in implementation and auditing of automotive quality management systems.

Benefits to Your Business
- Be able to plan and undertake effective and value adding internal audits using the modern process approach
- Understand the principles and practices of quality management system auditing
- Understand the principles and practices of manufacturing process auditing
- Have the ability to undertake internal and supplier audits

Course Structure
Topics include
- Types of automotive audit
- What is an audit? Auditing the ‘process approach’
- Types of internal audit – QMS, manufacturing process and product audits
- ISO/TS 16949:2002 internal audit requirements and auditor qualification
- The QMS process approach audit
- Audit preparation – establishing controlled conditions; undertaking the ‘virtual’ audit; concepts of the audit checklist
- Dealing with processes that do not have documented procedures
- Identify main process activities and support processes
- Evaluating the use of the ‘core tools’ and customer specific requirements
- Linking your processes to ISO/TS 16949:2002 clause requirements
- Developing an effective audit checklist
- Working with turtle diagrams and process maps
- Dealing with ‘what if’ and infrequent situations
- Developing probing automotive audit questions from QMS documentation
- Essential tips for audit checklists
- Using checklists in the design, development and manufacturing environment – the search for objective evidence
- Incorporating internal laboratory requirements
- Conducting the audit – the entry meeting; questioning techniques; open and closed questions; active listening; recording the evidence; making your decision (conformance/nonconformance); categorizing nonconformances
- Presenting audit findings – preparing nonconformance notes; the exit meeting; working with executive management addressing the findings – delineation of the roles of the auditor and management; determining root cause(s) and actions; recording corrective actions; monitoring implementation
- Closing out the audit – follow-up activities; the need for a follow-up audit; dealing with tardiness and ineffective corrective actions; preparing an audit (summary) report
- Scheduling internal audits – planning audits (understanding the criteria)
- Designing a effective and user-friendly audit planner; tracking progress; updating the audit planner
- Audit results input to management review and their role in continual improvement

The manufacturing process audit:
- Definition of a manufacturing process audit – objectives of the audit; what must be established; working with ‘big rules’; determining that the entire manufacturing process is capable
- Applying the manufacturing process audit to verify that ISO/TS 16949:2002 mandatory requirements are met
- Mapping the major manufacturing process activities – using the manufacturing process flowchart operator factors; customer complaints/problems; part certification requirements
- Manufacturing process audit preparations – identifying the essential documents and information (eg the PPAP file; product engineering specification; production and inspection information; FMEAs, control plans; set-up specification; work instructions; etc)
- Checking identified documents and records
- Checking part approval and capability of special characteristics
- Checking for customer complaints and internal/external ‘problems’
- Checking manufacturing sequence
- Workshop session #6
- Determining the manufacturing sequence – swim-lane process mapping and process layout diagrams – validating the process flowchart/layout
- Generic manufacturing process audit questionnaire – customizing the questionnaire
- Assessing customer satisfaction with the part – part quality, delivery performance, customer disruptions, customer notifications (quality and delivery issues), etc
- The essential opening meeting
- Conducting the audit – the need for a photographic record
- Recording evidence as-you-go – feedback to production personnel
- Dealing with ‘recalls’, ‘notifications’ and ‘service concerns’
- Evaluation and reporting – responsibilities for action
- Presenting the results - management, supervision, operators
- Verification of corrective actions
- Follow-up activities and manufacturing process audit closure

Further Information
Fee: Two-day course* including refreshments, lunch and course notes – £660 + VAT.
Attendance on this course will provide delegates with 16 CPD points.