Course overview
If you need to conduct effective internal IATF 16949 audits – then this is the e-Learning course for you!
This course is suitable for Internal Auditors and Supplier Auditors
TEC have packaged everything needed into this practical e-Learning course to ensure that participants will feel confident to plan, prepare, perform and report the results of audits based on IATF 16949 using an automotive ‘process-based approach’ including 'risk-based thinking' – in the same way as the Certification Bodies.
downloadable delegate notes are included with this e-Learning course
You will be learning how to audit using the supplemental IATF 16946 requirements (9.2.2.1 and 9.2.2.2) as well as the ISO 19011:2018 guidance in the same way as CB Auditors. Your competency will meet the requirements of 7.2.3 for internal auditors.
Course details
Preamble
Prior knowledge
Introduction – audits and audit terminology
What is an audit?
Test: defining an audit
Auditing interested parties & their requirements
Quiz: QMS and interested parties' requirements
Types of QMS audits
Quiz: types of audit
Extent of internal audits
Auditing guidance
Quiz: internal audits and ISO 19011
Elements and activities of an audit
Audit objectives, scope and criteria
Quiz: audit objectives, scope and criteria
Audit activities and ‘targets’
Quiz: understanding audit objectives, purpose, scope and objective evidence
Understanding responsibilities for auditing
Role of the 'management representative'?
Internal auditor competence (knowledge & skills)
Private assignment: how to have your auditing skills evaluated
Understanding requirements for an audit program
Criteria for scheduling an audit programme
Justifying an audit programme
Quiz: understanding requirements relating to internal audits
Understanding the structure of a QMS
Organization purpose, strategic direction and scope
Quality objectives
Quality objectives and the P-D-C-A cycle
Quiz: understanding quality objectives
Responsibility for quality policy & quality objectives
Exercise: creating basic audit questions
Advisement: specimen audit questions
Understanding a 'process approach'
QMS processes
Quiz: understanding a QMS process
Describing process sequence & interaction
Test: evaluating descriptions of the sequence & interaction of processes
Understanding process planned arrangements
Quiz: matching a process with its purpose
Understanding process controlled conditions
Test: identifying the ‘limbs’ of a Turtle diagram
Sources of process-based audit questions
Audit questions for Inputs/Activities/Outputs will be specific to each operation process
Understanding requirements
Standard requirements relating to QMS processes
Quiz: operation processes
Quiz: support (resources/assets)
Quiz: ancillary processes
Understanding standard ‘minimum’ requirements
Quiz: applicability of requirements as audit criteria
Understanding ‘applicable’ requirements
Quiz: applicability of IATF 16949 requirements
Private study: the QMPs & core concepts
Locating and understanding IATF 16949 requirements
Locating standard requirements
Understanding the structure of IATF 16949
Quiz: locating IATF 16949 requirements
Requirements for OPERATION processes
Quiz: locating IATF 16949 clauses applicable to operation processes
Requirements for SUPPORT (resources/assets)
Quiz: locating Table of Contents applicable to support (resources/assets)
Requirements for ANCILLARY processes
Quiz: locating IATF 16949 applicable to ancillary processes
Requirements for monitoring
Quiz: locating requirements for monitoring
Where are we now? ~ progress review
Overview of the audit process
Elements of an audit
Audit scope and criteria
Test: audit scope and audit criteria
Audit objectives and purpose
Test: audit objectives and audit purpose
Developing an audit program
Requirements for the audit program
Quiz: requirements for an internal audit program
Responsibility for the internal audit program
Auditor competence
Internal auditor selection
Test: internal auditor qualities
Audit planning
Audit planning and leadership
Planning considerations
Identifying ‘audit trails’
Private study: identifying a 'value-stream' audit trail
Advantages of following an audit trail
Different audit methods
Exercise: identifying different audit methods
Remote auditing
Document review
Understanding documented information
Quiz: mandatory documented processes
Introduction to sources of questions
Identifying people to audit
Identifying people-related audit criteria
Exercise: mapping QMS topics to IATF 16949 clauses
Developing effective audit questions
Basic elements of audit questions
Turning requirements into audit questions
Exercise: audit questions from IATF 16949 requirements
Advisement - specimen audit questions
Format and style of audit questions
Exercise: turning closed questions into open questions
Advisement - specimen open questions
Preparing work documents
Formulating audit questions for planned arrangements
Quiz: sources of audit criteria
Operation processes – planned arrangements
Exercise – creating audit questions for an operation process
IATF 16949 audit checklist
Ancillary processes – planned arrangements
Exercise – sequencing audit questions for an ancillary process
Formulating audit questions for controlled conditions
Exercise: Relating resource clauses to Turtle diagram 'limbs'
Formulating audit questions for risk-based thinking
Exercise: operation process risks, things to look for
Formulating audit questions for top management
Exercise: developing audit questions for top management
Advisement: ideas for top management audit questions
Formulating audit questions for quality policy
Quiz: auditing quality policy requirements
Formulating audit questions for continual improvement
Quiz: auditing continual improvement using the P-D-C-A cycle
Creating an audit work document
You’re now equipped and ready to undertake the audit!
Conducting an opening meeting
Purpose & agenda items
Exercise: creating an opening meeting agenda
Identifying evidence and taking samples
The ‘evidence-based approach’ to auditing
Audit sample size determination
Quiz: choosing an appropriate sample focus (operators)
Quiz: choosing an appropriate sample criteria (POs – purchase orders)
Quiz: choosing an appropriate sample size (FAIRs – First Article Inspection Reports)
Managing interviews & recording evidence
Reminder: auditor questioning techniques
Building rapport with the auditee
Don’t be intimidated by top management!
Collecting and recording objective evidence
Evaluating objective evidence & interview information
Evaluating the audit evidence
Criteria for determining nonconformities
Test: determining a nonconformity against an IATF 16949 clause
Dealing with recurring nonconformities
Beware of ‘observations’ or ‘OFIs’
Test: dealing with auditee disagreements
Communicating during audit
Creating effective NCRs (nonconformity reports)
Format and contents of an NCR
Specimen NCR
Test: legitimacy of an NCR
Test: understanding & locating elements of an NCR
Recording multiple instances of nonconformities on one NCR
Test: identifying a nonconformity and creating an NCR
Advisement: specimen (acceptable) NCRs #1 & #2
Grading NCRs
Auditing unanticipated situations
Adding questions during an audit
Exercise: creating ad hoc audit questions
Specimen audit questions
Preparing for and managing the closing meeting
Reviewing the audit findings
Agreeing the audit conclusions
Conducting closing meeting
Exercise: creating a closing meeting agenda
Reporting the audit results
Creating an audit report
Exercise: creating an audit report
Conducting audit follow-up
Auditor and auditee responsibilities
Recording the results of corrective actions
Auditing and evaluating nonconformity & corrective action
Test: categorizing root causes using 'cause-codes' criteria
Reviewing and evaluating resulting corrective actions
Verify corrective actions
Quiz: evaluating corrective actions
Qualifications & benefits
The benefits of e-learning are numerous; not only are they extremely cost-effective but they provide students with convenience and flexibility as they embark on their learning journey. You can complete your training whenever and wherever you want, and at your own pace.
Companies do not have to tie-up entire teams at the same time as is the case with conventional classroom-based training.