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IATF 16949 Internal/Supplier Auditor Training

Programme overview

If you need to conduct effective internal IATF 16949 audits – then this is the practical ‘face-to-face’ course for you!

this course is suitable for both Internal Auditors and Supplier Auditors

TEC have packaged everything needed into this practical 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.

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 IATF 16946 requirements of 7.2.3 for internal auditors.

Programme details

Preamble

  • Prior knowledge and standards
  • ISO 9001:2015 and IATF 16949:2016 relationship

Introduction – audits and audit terminology

  • What is an audit?
  • Audit-related terminology
  • Test: defining an audit (fill in the blanks)
  • Auditing interested parties & their requirements
  • Quiz: QMS and interested parties' requirements
  • Types of QMS audits
  • Extent of internal audits
  • Auditing guidance (ISO 19011:2018)

Elements and activities of an audit

  • Define audit objectives, scope and criteria
  • Quiz: audit objectives, scope and criteria
  • Understand the activities and 'targets' of the internal audit process

Elements and activities of an audit

  • Audit objectives, scope and criteria
  • Quiz: audit objectives, scope and criteria
  • Understand the activities and 'targets' of the internal audit process

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 program
  • Justifying an audit program
  • Quiz: understanding requirements relating to internal audits

Understanding the structure of a Quality Management System (QMS)

  • Organization purpose, strategic direction and scope
  • Quiz: what are the benefits of and effective QMS?
  • 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
  • Tutor advisement: specimen audit questions

Understanding a 'process approach'

  • QMS processes
  • Exercise: requirements for a process approach
  • 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 processes
  • Quiz: ancillary processes
  • Understanding standard ‘minimum’ requirements
  • Reminder: determining conformity
  • Quiz: applicability of requirements as audit criteria
  • Reminder: identifying applicable 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 processes
  • Quiz: locating IATF 16949 applicable to support processes
  • Requirements for ANCILLARY processes
  • Quiz: locating IATF 16949 applicable to ancillary processes
  • Requirements for monitoring, measurement, analysis and evaluation
  • Quiz: locating specific requirements for monitoring
  • Exercise: auditing customer satisfaction process
  • Tutor advisement: auditing customer satisfaction process
  • Exercise: auditing supplier performance
  • Tutor advisement: auditing supplier performance
  • Where are we now?

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
  • IATF 16945 requirements for an internal audit program
  • Responsibility for the internal audit program
  • Auditor competence
  • Auditor competence – IATF 16949 requirements
  • Internal auditor selection
  • Test: internal auditor qualities

Audit planning

  • Audit planning and leadership
  • Illustration: audit plan for the entire QMS
  • Illustration: audit plan for design & development process
  • Illustration: audit plan for production process
  • 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
  • Mandatory requirements for documented information
  • Quiz: mandatory documented information

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
  • Format and style of audit questions
  • Exercise: turning closed questions into 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
  • Tutor advisement: specimen audit questions for an operation process
  • IATF 16949:2016 audit checklist
  • Ancillary processes – planned arrangements
  • Formulating audit questions for controlled condition
  • Exercise: Relating resource clauses to Turtle diagram 'limbs’
  • Formulating audit questions for risk-based thinking
  • Identifying risk sources and related methodologies
  • Exercise: operation process risks, things to look for
  • Formulating audit questions for top management
  • Exercise: developing audit questions for top management
  • Tutor 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
  • Creating an audit work document from a Turtle diagram
  • You’re now equipped and ready to undertake the audit!

Conducting an opening meeting

  • Purpose of an opening meeting
  • Agenda items for an opening meeting
  • 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)
  • Layout inspection and functional testing PPAP (Production Part Approval)
  • Quiz: choosing an appropriate sample size (Layout inspection and functional testing)

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

  • Evaluate 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
  • Tutor advisement: understanding & locating elements of an NCR
  • Recording multiple instances of nonconformities on one NCR
  • Specimen NCR used by CBs
  • Test: identifying a nonconformity and creating an NCR
  • Tutor advisement: specimen (acceptable) NCR
  • Grading NCRs
  • Test: grading NCRs (minor/MAJOR)

Auditing unanticipated situations

  • Adding questions during an audit
  • Exercise: creating ad hoc audit questions
  • Tutor advisement: specimen ad hoc audit questions

Auditing and scoring process effectiveness

  • Understanding process effectiveness
  • Conducting an effectiveness audit
  • Issuing an NCR against deficient effectiveness
  • Test: scoring process effectiveness (PEAR)

Preparing for and managing the closing meeting

  • Reviewing the audit findings
  • Agreeing the audit conclusions
  • Escalation of NCR gradings
  • Conducting a closing meeting
  • Exercise: creating a closing meeting agenda

Reporting the audit results

  • Creating the audit report
  • Exercise: creating an audit report

Conducting audit follow-up

  • Auditor and auditee responsibilities
  • Recording the results of corrective actions
  • Specimen NCR used by CBs (auditee section)
  • Auditing and evaluating nonconformity and corrective action
  • Categorization of root causes
  • Human factors
  • Reviewing and evaluating resulting corrective actions
  • Quiz: evaluating corrective actions
  • _Corrective action – example #1, #1 & #3

Next actions

  • Follow-on coaching and qualification

Who should attend

The course is primarily aimed at individuals who are required to conduct internal and supplier audits covering conformity and compliance against IATF 16949:2015 requirements.

Participants are not required to have any previous experience of auditing or a detailed understanding of the IATF 16949:2015 clauses – it’s learn-by-doing or accelerated learning.

Qualification

Individuals who successfully complete the course will –

  • be better equipped to maintain conformity with IATF 16949:2015
  • be able to undertake an in-depth 'gap analysis' of an existing IATF 16949:2015 QMS
  • be confident in knowing that their audit questions address all important issues
  • identify weaknesses in QMS performance (e.g. quality and delivery) and process-level effectiveness
  • conduct effective evaluations of 'Leadership' by auditing Top Management
  • identify risks and opportunities within the QMS

All students successfully completing the 2-day 'face-to-face' course will receive a training certificate containing the TEC's internationally-recognized logo.

The organization will –

  • be confident that their auditors are empowered to undertake effective IATF 16949:2015 internal and supplier audits
  • know that the outcomes of the audits will meet the expectations of Certification Bodies and automotive customers
  • ensure conformity, maintenance and ongoing improvement of the QMS

Upcoming courses

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