IATF 16949:2016 Lead Auditor Training for Automotive Quality Management Systems

Seminar Content

The new Automotive Quality Management System requirements have been rebranded as IATF 16949:2016 (formerly ISO/TS 16949:2009). Although the ISO 9001 requirements have been removed from IATF 16949:2016 and are published as a separate ISO standard, IATF 16949 is not a stand-alone standard and must be used in conjunction with ISO 9001, so Omnex is continuing to offer courses that cover both the ISO 9001:2015 and IATF 16949:2016 requirements.
Omnex is an Exemplar Global Certified TPECS provider for Exemplar Global QM, AU and TL Competency Units. This five-day course has been developed to satisfy the Exemplar Global QM, AU and TL Examination Profiles and, as such, all attendees who successfully pass the exams during this course will achieve a Certificate of Attainment for the following competency units:

• Exemplar Global QM
• Exemplar Global AU
• Exemplar Global TL

This five-day course was developed to cover all requirements of both the ISO 9001:2015 and IATF 16949:2016 standards, including the new IATF 16949 requirements for Internal and Second Party Auditors (clauses 7.2.3 and 7.2.4) regarding Core Tools and Customer-Specific Requirements. Group exercises and case studies with examples from the automotive industry will be used to develop the required auditing skills. The auditing guidelines of ISO 19011 including the auditing process and methodologies, e. g., planning and conducting an audit, writing nonconformity statements, preparing an audit summary and report, and verifying corrective actions and their application in the automotive process approach are covered. Auditing case studies from the automotive industry to develop skills for identifying nonconformities will be used. Techniques for leading audit teams will also be discussed.

Who Should Attend

This seminar is primarily designed for internal or third party auditor candidates, but can also be valuable for Quality Assurance Managers, IATF 16949:2016 Implementation and/or Transition Team Members, Management Representatives, and all others who would like to develop competency in IATF 16949:2016 and the auditing process for first, second and third party auditing.

Recommended Training and/or Experience

An understanding of both ISO 9001:2015 and IATF 16949:2016 requirements and/or work experience in applying IATF 16949:2016 is recommended.

Seminar Materials

Each participant will receive a seminar manual and a breakout workbook that includes automotive-based auditing case studies.

Seminar Goals

• Understand the application of quality management principles in the context of ISO 9001:2015 and IATF 16949:2016.
• Relate the quality management system to the organizational products, services, activities and operational processes.
• Relate organization’s context and interested party needs and expectations to the planning and implementation of an organization’s quality management system.
• Understand the application of the principles, procedures and techniques of auditing.
• Understand the conduct of an effective audit in the context of the auditee’s organizational situation.
• Understand the application of the regulations, and other considerations that are relevant to the management system, and the conduct of the audit.
• Practice personal attributes necessary for the effective and efficient conduct of a management system audit.
• Establish, plan and task the activities of an audit team.
• Communicate effectively with the auditee and audit client.
• Organize and direct audit team members.
• Prevent and resolve conflict with the auditee and/or within the audit team.
• Prepare and complete the audit report.
• Understand the purpose and applicable uses of the core tools
• Link the core tools to IATF 16949:2016 requirements
• Explain the importance of Customer-Specific Requirements

Seminar Outline

Day One

• Introduction and Welcome
• The ISO and IATF Standards Explained
• Introduction to ISO 9001 and IATF 16949
• ISO 9001:2015 and IATF 16949:2016 Requirements
  • Group Exercise: Context of the Organization
  • Group Exercise: Interested Parties
  • Group Exercise: Audit Scenarios

Day Two

• ISO 9001:2015 and IATF 16949:2016 Requirements (cont’d)
  • Group Exercises: Audit Scenarios (cont’d)
  • Independent QMS Written Exercise
• Introduction to Turtle Diagrams and Audit Trails
• Management of Audit Programs
• Audit Planning and Preparation
  • Breakout Exercise 1: Writing an Objective and Scope Statement
  • Breakout Exercise 2: Documentation Review
  • Breakout Exercise 3: Creating an Audit Plan

Day Three

• Performing the Audit
  • Breakout Exercise 4: Performing an Audit
    • Conducting a Process Approach Audit
    • Conducting an Audit of Risk Planning (6.1)
• Writing Nonconformity Statements
  • Breakout Exercise 5: Writing Nonconformity Statements
• Closing Meeting
• Completing the Audit Report
• Corrective Action and Closeout

Day Four

• Linking Automotive Core Tools to IATF 16949
• Customer-Specific Requirements
  • Management Systems Auditing Written Exercise

Day Five

• Leading Audit Teams
• Management System Certification Scheme and Auditor Qualifications
  • Leading Management Systems Audit Teams Written Exercise
• Review of Audit Process and Audit Management Strategies
  • Leading Management Systems Audit Teams Mock Audit Case Study
    • Including scenarios on Risk-Based Thinking and a Process Flow/PFMEA/Control Plan Manufacturing Process Audit Scenario
• Practical Application of Audit Principles and Instructor Interviews

VDA 6.3 – Qualification for Process Auditor

Days: 4 

Learning Objectives:

Based on the ISO9001 process approach, the basis of IATF 16949 and its specific
customer requirements, this 4-day training provides the basis for VDA 6.3 process
auditors. The introduction to basic audit techniques includes general requirements,
methods, principles and risk analysis. This introduction enables the trainee to
understand correlations and to apply and implement the correct chain of activities
during the audit. These steps will guide the trainee through the general
requirements of process audits and will enable the trainee to take a holistic
approach to the Automotive Industry.
This training also enables the trainee to apply requirements P1 to P7 of the VDA 6.3
questionnaire through the supply chain, based on the respective interpretation and
practical examples. The purpose of this training is to provide training to conduct
process audits through the supply chain, the ability to identify risks and determine
the potential of new suppliers. This approach is applied to the correction,
stabilization and improvement of processes and is presented through exercises and
examples. The aim is to ensure a robust assessment.

AGENDA

1. Quality Systems, Application and Benefits for Process Audits (ISO9001, IATF 16949).
2. Quality Management Methods (Approval of Initial Samples, Control Plans, Quality Plans, Risk Analysis [FMEA,…], Problem Solving Methods,…).
3. Risk Analysis with the “Turtle” Method.
4. Communication, Ethics and Code of Conduct.
5. Customer requirements and their interpretation (VDA requirements, customer-specific requirements [CSR, …]).
6. Steps of Process-oriented Auditing (from preparation to implementation).
7. Planning and Conducting the Process Audit.
8. Preparation of the Audit.Adding GD&T to a Design
9. Application of the respective questionnaires, including Potential Analysis.
10. Complement the Questionnaire through the Audit Preparation.
11. Client Requirements and their Interpretation (VDA Requirements, Client
Specific Requirements [CSR,…]).
12. Evaluation and Evaluation Rules.
13. Documentation and Conclusion.

4 Day IATF 16949:2016 AND ISO 9001:2015
Internal Auditor Class

Days: 4

Time:  7:30 AM- 5:30 PM MST

Monday- Wednesday ISO 9001:2015, AND Friday IATF 1649:2016

Audience: Beginner to Advanced

Overview

This course prepares you to perform internal QMS audits using industry-proven techniques and to apply proper interpretation of the ISO standard to real-life audit situations. You’ll follow the full audit process including: audit tools and preparation, opening meetings, audit interviews, closing meetings, and reporting. This is a very practical class that is not “bogged-down” with academic discussions of quality topics that have limited utility for class attendees.
This class teaches Internal Auditing for IATF 16949:2016 AND ISO 9001:2015 Quality Management System.
This Internal Audit class makes extensive use of activities and case studies to help you fully understand the requirements of quality system auditing to the IATF 16949:2016 AND ISO 9001:2015 standard. Since people “lock” new understanding into long-term memory much better when they apply it, lecture time is held to a minimum providing you time to grasp and then practice your newly acquired skills in simulated real-life audit situations.

Who Should Attend

Individuals who will perform audits to IATF 16949:2016 AND ISO 9001:2015 standard for Quality Management Systems, individuals assisting their organizations toward IATF 16949:2016 AND ISO 9001:2015 registration, or individuals who are frequently audited should attend this training. Quality directors, managers, engineers, auditors, ISO coordinators, laboratory quality professionals, and anyone engaged in quality audits will benefit from this training.

Prerequisites

There are no required prerequisites. This course is routinely taught to quality novices and life-time professionals. All attendees are required to bring their own copy of the IATF 16949:2016 AND ISO 9001:2015 Quality Management Standard Requirements to this training course. These will not be provided for you. We strongly advise you bring a “paper” copy.

Course Objectives

• Prepared to conduct a solo internal audit at successful course completion
• Fully understand and interpret the ISO requirements
• Apply the proper interpretation of the standard in actual audit situations
• Understand process auditing tools leading to substantive quality system improvements
• Tailor an audit interview based on the requirements of the standard and obtain audit evidence from this interview
• Follow-up and resolve “audit trails that present themselves during the audit interviews”
• Conduct audits that result in real improvements to the quality system
• Plan and execute the entire audit process including audit preparation, opening meetings, auditing, closing meetings, and reporting.

Agenda

Part 1: Introductions and Self-Assessment

1. Course requirements
2. How to get the most from this experience
3. Networking with classmates (industry professionals)
4. Self-assessment of audit skills and internal audit programs Exercise #1

Part 2: Terminology and Definitions

1. Industry vernacular from ISO 9000, ISO 19011, IATF 16949:2016 AND ISO 9001:2015
2. Differentiating between Verification and Validation
3. Understanding Corrective Actions and Risk Management
4. How to converse with external auditors
5. Terminology Exercise #2

Part 3: Requirements of IATF 16949:2016 and ISO 9001:2015

1. Demystifying the IATF 16949:2016 AND ISO 9001:2015 standard
2. Interpreting and cross-referencing the quality standard
3. Analyzing audit findings
4. Audit exercises for the application of ISO standard to quality events
5. Exercise #3-#7: Short case studies in quality events

Part 4: Implementing IATF 16949 and ISO 9001:2015

1. Strategic Planning Elements of 4.1, 4.2, 6.1, and 9.3
2. Risk-based Elements of 6.1, 7.5.1, and 8.1
3. Action Plan Elements of 6.2
4. Differences in Documentation and Other Requirements
5. Timetable for Transition of Certification to ISO 9001:2015 and IATF 16949:2016
6. Individualized Transition Road Map

Part 5: The Audit Process: Roles and Duties

1. Roles of Auditors, Auditees, and Management during Internal Audits (IAs)
2. Qualifying Auditors
3. Duties of the IA staff
4. Exercise #8: Preparing to be audited

Part 6: The Audit Process: Performing the Audit Process

1. Audit Tools – checklists, process maps, findings, reports
2. Conducting Audit Interviews Exercise #9
3. Exercise #10 QMS event case studies

Part 7: The Audit Process: Audit Skills and Techniques

1. Audit Interviewing techniques
2. Continual improvement techniques
3. Process Auditing methods
4. Developing a “continual improvement” attitude in the organization
5. Exercise #11 Writing Audit Findings
6. Exercise #12 Evaluating the effectiveness of Audits
7. Exercise #13 Application of Process Auditing techniques

Part 8: The Audit Process: Finalizing the Audit

1. Writing the audit report
2. Opening and Closing Meetings
3. Exercise #14 Writing and audit report
4. Exercise #15 Writing Non-Conforming Reports
5. Exercise #16 Conducting a Closing Meeting

Review and Examination for Certificate

________________________________________________________________

Automotive Core Tools Training

for Process and System Auditors

Days: 2

Overview

In order to ensure a high initial quality of audit activities in the companies and the entire supply chain, the appropriate competence of the auditors employed in relation to the respective methods is required. The IATF 16949 also clearly highlights this requirement for the competence of the auditors. The efficient approach during the audits is an important success factor. This training focuses on typical audit situations along the Automotive Core Tools.

Who Should Attend?

This training is intended for employees from the Quality department and/or other departments of the organization who wish to acquire knowledge about the main Core Tools of the Automotive Industry or develop their skills in performing typical auditing situations in this context. This two-day training course is also aimed at qualified VDA 6.3 process auditors who wish to apply for an extension, as well as prospective VDA 6.3 Process and IATF System auditors who are seeking qualification.

Course Objectives

The participants strengthen their technical competence and deepen their knowledge on the basic of typical auditing situations in the context of quality methods, focusing on an efficient approach. Both the assessment of the technically correct application of the respective methods and the case-specific assessment of typical situations are a central component of the training.

Methods and Duration:

During the training, technical lectures on the essential Core Tools (APQP, VDA 2 / PPAP, FMEA, VDA 5 / MSA, Cmk / Ppk / Cpk / SPC and 8D) will be alternated with exercises in typical examples.
The focus is on practical application by the participants. Here, group work, individual exercises, question and answer exercises, as well as group discussions will be held.
The exploration of the course contents will alternate between some thematic exhibitions and practical exercises based on the professional reality of the participants.
Theoretical-practical training, with application to real cases, lasting 16 hours (2 days).

Maximizing the ROI from your Quality Management System

Days: 1

Time: 7:30 AM-4:30 PM MST

Audience: Top management

Overview 

A Quality Management System is NOT a cost of doing business.  It’s an investment.  And top management should expect to get a financial return on that investment.  However, the Return On Investment (ROI) they receive will be greatly impacted by the level of leadership and commitment they provide concerning the management system.

The newest versions of most ISO management standards have amplified the requirements for top management, in accordance with ISO 9001:2015.  In this highly interactive course, senior managers will learn how to fulfill their new responsibilities, take accountability, and maximize the ROI they get from their management systems.

Why Attend?

This class will help to show the true value of your quality management system and how much it really adds to your bottom line. It will also help your company to increase the ROI of your QMS.

If you want to improve your company’s bottom line or show your boss how much your QMS is already contributing to profits then this class is for you.

Who Should Attend?

• Top management from organizations with quality, environmental, or safety management systems, including chief executives, general managers, and other senior managers.
• Quality Managers and/or Management Representatives
•  Anyone considering implementing an ISO quality system

Course Objectives

• Understand the new top management ISO requirements and how to accomplish them.
• Understand the responsibilities that can be delegated to a management representative, and those responsibilities top management must retain.
• Learn how to maximize the ROI from your management system.
• Receive practical methods, tools, and tips for using your QMS to enhance organizational performance.
• Learn the mistakes to avoid that can negatively impact your management system.
• To provide decision-makers with information that will help them to provide direction for their existing or planned quality management system

Agenda

Benefits of a Quality Management System

• Overview of Potential Benefits, including Return on Investment (ROI)
• Why Top Management Leadership and Commitment is Important.
• Creating an Organizational Culture that Supports Quality.

Overview of Quality Principles

• What is Quality?  What is Quality Management?
• Top Management Responsibilities (per ISO 9001) and How to Accomplish Them.

How to Maximize the ROI from your QMS

• ROI Depends on an Organization’s Level of Commitment to its QMS System.
• Using your QMS processes to ensure Customer Satisfaction and Increase Profitability.
• Using the Process Approach to Manage Quality (Turtle Diagram).
• Establishing KPIs and Determining Process Effectiveness.
• Continuously Improving your QMS.
• Reducing the Costs of Poor Quality (COPQ).
• Using Your QMS to Manage Risks and Support Your Strategic Direction.

The Five Biggest Mistakes Executives Make with Quality Management

Final Test