Professional Documents
Culture Documents
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.
IATF Members
Authoring Organization of ISO/TS 16949 includes:
IATF Oversight
ANFIA, IAOB, IATF-France, SMMT, VDA-QMC
Purpose of IAOB
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:
Automotive application
Line of sight from the organization to the customer
Audit plan
Performance
Oversight
R
E
Q
U
I
R
E
M
E
N
T
S
Management
Responsibility
Resource
Management
Inputs
C.I.
Product
Realization
Measurement,
Analysis
& Improvement
Product
Outputs
C
U
S
T
O
M
E
R
S
A
T
I
S
F
A
C
T
I
O
N
ISO / TS 16949
Parts or materials
Heat treating, painting, plating, other finishing services
Other customer specific products
Was
Subcontractor
in QS-9000
Was
Supplier in
QS-9000
Automotive Specific
Terminology
Adds sector terminology
Control plan
Design responsible org.
Error proofing
Laboratory
Laboratory scope
Outsourcing
Predictive maintenance
Premium freight
Remote location & site
Special characteristics
Continual improvement
Manufacturing
ISO / TS 16949
Permissible Exclusions
The only permitted exclusions may be in 7.3
Mandatory Procedures
ISO 9001:2000
Control of Documents
Control of Records
Internal Audit
Control of
Nonconforming Product
Corrective Action
Preventive Action
ISO/TS 16949:2002
Laboratory
Field Service (i.e.
Warranty)
Training
TS-16949:2002
(Process Based)
(Procedure Based)
Procedures Are:
Processes Are:
Issued
Managed
Are segmented
Flow to conclusion
Static
Dynamic
Management of Processes
Process 2
Process 3
Process 4
Functional Goals
3
4
es
s
Pr
oc
Process 1
go
als
A FUNCTIONAL
ORGANIZATION
WITH PROCESS
OVERLAYS
Recognizes:
Objectives
Inputs
Stakeholder Wants & Needs
Specifications
Schedule/Timing
Market Data
Industry Trends
Economic Conditions
Risks
Process
Outputs
Products
Information
Results
Process Mapping
Marshall Key Processes
Manufacturing
Shipping
Support Processes
Business Processes
LRP/OP
Manufacturing
Roadmap
CQR/CQA
Component Quality
Information
Management
Document
Control
Asset Management
Human Resource
Management
Non-conforming
Material
Materials
Management
Capacity Planning
Purchasing
DFM
Supplier
Management
Customer Support
Laboratory
Records Retention
5S Audit
Corrective
Action
Internal Auditing
Management
Review / Continuous
Improvement
Quality
Objectives
Supporting Instructions
Forms and Form Instructions
Preventive Action
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.
Inputs/Suppliers
345643/ERD 2345
P ro cess R isks:
P ro cess M easurables:
Suppo rt P ro cesses:
1. On-time delivery.
Configuration M anagement
M anufacturing
ProgramM anagement
Purchasing
Inputs
P ro cess
(1) Receive
Customer P.O.,
EDI, Phone, Fax,
M ail
Customer
Order
Outputs
Test
Issues ?
Specifications
(7) Resolve
with the
Customer
No
Quality
Issues ?
No
(5) Components
Inventory Check
Components
Drawings
(8) Quality
Inspection
No
Y es
Revised
P.O.
Req'd?
No
Y es
Functionally Test
Prototypes
Order
Issues ?
(6) Build
Prototypes
Y es
(9) Resolve
with the
Customer
(10) Complete
Prototype
Paperwork
Prototype
Paperwork
Prototype
Parts
(12) Issue
Billing to
Customer
Customer
Invoice
Process Nam:
Document No.
Revision
MPM0078
P rocess M easurables:
Support P rocesses:
Ship quality product per 1. On-line system goes down and customer orders are missed.
customer requirements. 2. The wrong quantities are shipped.
3. The shipment is not on time to the customer schedule.
4. Customer not notified (no ASN)
5. No invoice or not correct.
6. Customer requirements not met.
M aterial M anagement
Inputs
P rocess
Document Control
Non-Conforming M aterial
Outputs
Report and
M ove to
Finished Goods
Warehouse
Storage
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:
Document No.
Revision
MPM0079
P rocess M easurables:
Support P rocesses:
Ship quality product per 1. On-line system goes down and customer orders are missed.
customer requirements. 2. The wrong quantities are shipped.
3. The shipment is not on time to the customer schedule.
4. Customer not notified (no ASN)
5. Dropped parts.
M aterials M anagement
Document Control
Non-Conforming M aterial
Inputs
P rocess
Delivery Note
fromCustomer
Service
Outputs
1. Shipping A ssociate
2. Shipping C lerk
Stored Finished
Goods
Consult SAP
inventory screen.
Is container
within the two
week window
of stock
No
Warehouse
Nonconformance
Y es
Y es
Is all stock
available?
Y es
No
Is the box
damaged or
dropped?
No
Is another box
required?
Shipment
Configuration
Is stock in
the correct
quantity?
Contact
M anufacturing or
Customer Service
Y es
No
4. DC X SM A R T System
5. Ford DDL
6. M M OG
No
Y es
Pull Order
Assemble order
per customer
directives
Governing Documents
1. C ustomer P ackaging Specifications
2. Delivery Note
Place on truck
Questions?