Course 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.
Course 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.
Deliverables & benefits
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