Automotive Training

Topics include:

• Types of automotive audit
• What is an audit? Auditing the 'process approach'
• Types of internal audit - QMS (quality management system), 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 check-list
• 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 check-list
• 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 check-lists
• Using check-lists 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 (e.g. 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