Details on ISO/TS 16949:2009

ISO/TS 16949:2009 gets redefined often as the standard evolves over time. Though the technical specification does not change, the definition, interpretation, and audit requirements have changed and/or evolved over time through Sanctioned Interpretations and FAQs. Most of the time the changes are focused on improvements based on required industry change.

Re certification Training

The competency matrix in turn has impacted the ISO/TS 16949:2009 Third Party Re certification Training. The Re certification training based on the competency matrix will have an impact in many areas, including:

• Process Approach
• Top Management Expectations,
• Customer Specifics
• nonconformity Writing
• Closeouts

The impact of the changes will affect both TS-registered and non registered organizations over time, as the organizations' ISO/TS 16949:2009 lead auditors get re certified. The first batch of auditors took the exam last November, and the last batch will take it within three years.

The Competency Matrix and Re certification Training impact is extensive. Here are some of the key changes:

• Process Approach -
1. Further emphasis on prioritizing the audit plan based on the risks to the customer
2. Focus on identifying a process-based Audit Plan versus a clause-based Audit Plan
3. Understanding a clause-based or function-based Process Map versus a process based Process Map
4. Identifying the processes for the Site and support functions on the process map
• Top Management Expectations - new interview requirements for top management were more clearly defined
• Customer Specifics - Prioritizing OEM customer specifics and auditing processes that have customer specifics already embedded in them
• Nonconformity Write Ups - Writing "system"- focused nonconformity
• Nonconformity Close Outs - Answering nonconformity with root causes, corrective and system corrective actions. Internal Audit nonconformity are treated similarly to customer 8-Ds or 7-Ds.

As organizations get audited this year, they can expect more major nonconformity for missing the "process approach" in process design and in auditing. Also, major nonconformity can be expected for write-ups and close outs of nonconformity.

Conducting Effective ISO/TS 16949:2009 Audits

The Problem with audits and auditors

The IATF and the automotive approach to process auditing have led many to rethink the processes associated with Third Party Audits. Many improvements in auditing practices for third party have resulted because of this emphasis on improving third party audits from the initial readiness review, to the process based audit plan, to even writing up non-conformances. Similarly, organizations performing internal audits need to improve their overall process for them.

Auditor competencies for ISO/TS 16949:2009 and ISO 9001:2008 can be evaluated using a competencies matrix developed by the IATF. This matrix has broken down auditor competencies into 113 different competency areas for 31 different activities. A third party registrar evaluating its auditor base concluded that there was a 38% deficiency in its third party auditors.

The competencies identified by the IATF do not even cover requirements to understand ISO/TS 16949:2009, Customer Specific Requirements, Core Tools or the auditing process described in ISO 19011:2002. These auditor competencies detail what types of knowledge and competency auditors need to have in readiness reviews and when performing Stage II audits.

After an internal audit is performed, does the organization feel they have understood the business areas and/or the processes to improve? Or is the internal audit another exercise identifying the leaves on the trees but missing the rot in the tree trunk? In other words, detailed items like document control and lack of training records are written up, but issues like losing a customer due to repeated problems and/or severe cost issues in new product launch go undetected?