IATF 16949:2016 Internal Auditor Training

By the end of this 2-day practical course and workshop participants will know how to plan and undertake internal and supplier audits using a ‘process-based approach’ and how to assess the ‘active’ management of customer satisfaction, QMS performance and process-level effectiveness - in line with the requirements of IATF 16949:2016. Special attention is given to auditing the correct use of the automotive ‘core tools’.

The course is applicable to the October 2016 revision of the IATF 16949 standard. From 1st October 2017, all audits must be to IATF 16949:2016. Transition to IATF 16949:2016 must be completed by 14th September 2018.

Assessment of learning is achieved through structured exercises and real-world audit scenarios undertaken by the participants. The tutors provide feedback and advisement to ensure that best practice is fully understood in the context of the automotive and motorsport industries.

The 2-day course is highly interactive and uses group exercises and individual role-play scenarios. The course timings are -

  • Day #1: 08:30 – 17:00
  • Day #2: 08:30 – 17:00

Course topics include -

Introduction to IATF 16949:2016 process-based auditing

  • Terminology and purpose of auditing
  • Standards relating to automotive auditing
  • Understanding the interrelationships between QMS Requirements – Activities/Tasks/Procedures - QMS Processes - The QMS System
  • Identifying the audit ‘participants’ and explanation of the types of (QMS) audit
  • Overview of the TS16949 and ISO-Guidelines relating to auditing
  • Explanation of the need to evaluate conformity to all (QMS) requirements -
    • IATF 16949:2016 + Customer-specific requirements
    • routine use of the ‘core tools’
    • effectiveness of (product realization) processes
    • performance of the QMS
    • customer satisfaction

Preparation for a ‘process-based approach’ QMS audit

  • Applying the ‘process-based’ auditing methodology
  • Audit preparation using the ‘11-step’ approach -
    • Determine the organization type and operational structure – automotive and motorsport customers
    • Identify and name the key product realization processes
    • Identify ‘process owners’, key staff and process purpose
    • Review sequence and interaction of processes
    • Establish logical ‘audit trails’
    • Interview top management
    • Understand how each process operates – activities/tasks
    • Identify how ‘controlled conditions’ are imposed
    • Establish how process effectiveness is monitored
    • Relate process “controlled conditions” to applicable sub-clauses
    • Create the audit questions
  • Analysing objective evidence – ‘documents’ and ‘records’
  • Identifying mandatory IATF 16949 documents and records
  • Determining correct usage of the ‘core tools’ and other competency issues
  • Identifying key management/support processes and/or procedures plus ‘organization-specific’ SOPs
  • Analysing and auditing the mandated documented procedures - in context & stand-alone

Undertaking the audit

  • Combining ‘Process-effectiveness’ and ‘OER questions’ for IATF 16949 internal/supplier audits
  • Identifying ‘Killer Questions’
  • Commencing the audit – ‘Opening Meeting’
  • Communication during the audit
  • Using OER questions
  • Taking ‘representative samples’ (Judgmental Sampling)
  • Conducting the audit and evaluating objective evidence and statements-of-fact
  • Using the audit questionnaire form to record evidence and conformity decisions
  • Recording objective evidence and comments
  • Structured questioning techniques
  • Understanding ‘Active Listening’
  • Formulating WHAT (WHY), HOW and WITH WHAT ‘Open Questions’
  • Open and Closed question combinations
  • Auditor dos and don’ts
  • Auditing tips – recording objective evidence
  • Writing effective NCRs
  • Creating NCRs for QMS problems
  • Creating NCRs for process effectiveness deficiencies
  • Creating NCRs for QMS performance
  • Grading NCRs as MAJOR or minor
  • Writing out correctly ‘crafted’ NCRs

Reporting audit findings and following up the audit

  • Preparing audit conclusions – considerations and actions
    • conformity issues
    • competency issues (with special reference to the ‘core tools’)
  • Presenting the findings – ‘Closing Meeting’
  • Handover to management and process owners!
  • Systematizing nonconformity management
  • Understanding ‘containment actions’
  • Understanding audit responsibilities
  • Approaches and methodologies for RCCA (root cause corrective action)
    • Seeking root causes from ‘3-perspectives’
    • Using Fishbone Diagrams and 5-Whys in combination
    • Avoiding ‘human error’ classification for root causes!
  • Evaluating (management) corrective actions and closing-out NCRs
  • Avoiding the re-occurrence of NCRs

The Audit Report

  • Audit report contents – recommended items for IATF 16949 audits
  • Approving and distributing the audit report

Planning (internal and suppliers) audits

  • Audit planning guidelines
  • Understanding IATF 16949 expectations
  • Planning the ‘audit day’ – including Opening & Closing Meetings and Communications Meetings
  • Sharing the workload between audit team members

Scheduling (internal and suppliers) audits

  • Prioritizing audits – the ‘Internal Audit Planner’
  • Updating the internal audit planner

Extended Q & A session

Public course

Our public courses are run at the Woodland Grange Conference Centre in Warwickshire

The course fee includes a 3-course lunch and refreshments during both days

Course dates
On-site course

In-company courses may be organised at any time and are extremely cost-effective on a ‘cost-per-student’ basis. The host company is responsible for the venue costs.

We can accommodate up to 10 (maximum) delegates per session.

Details/quote
Individuals wishing to need to conduct internal and supplier audits against the stringent requirements of TS16949, and those who want to monitor process effectiveness and QMS performance.

Individuals who successfully complete the course will -

  • be better equipped to maintain compliance with IATF 16949 requirements
  • focus on the 'core tools' to assess effective usage
  • be confident in knowing that their audit questions address all important issues
  • identify weaknesses in QMS performance (e.g. quality and delivery), process-level effectiveness and leadership
  • identify risks and opportunities within the QMS
  • be able to accrue CPD points because of the highly structured nature of this course

All students successfully completing the 2-day course will receive an individual training certificate containing the TEC Transnational logo

The organization will –

  • be confident that their auditors are empowered to undertake effective IATF 16949 internal (and supplier) audits
  • know that the outcomes of the audits will meet the expectations of automotive/motorsport customers and Certification Bodies

Larger teams might benefit from our in-house courses. Fill out the form below and we will contact you with further details.

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