SMMT IATF Oversight CB Feedback meeting performance review

Transcription

1 SMMT IATF Oversight CB Feedback meeting performance review 21 st November 2014 SMMT, the 'S' symbol and the Driving the motor industry brandline are trademarks of SMMT Ltd

2 Agenda Part 1 Performance - Certificates - IATF KPI - Nonconformity analysis Part 2 Scheme update - Adoption of ISO9001:2015? - MAQMSR - Rules 4 th SI/FAQ update - IATF database functionality changes - PSA database initiative - Support functions - ADP update - Witness audit report format changes - Any other business - Training meeting schedule PAGE 2

3 Certificate end Oct 2014

4 Global Distribution North America 10.2% (5,826) Europe 19.1% (10,877) Asia Pacific 64.3% (36,655) C & S America 2.8% (1,600) Africa 0.8 (470) Middle East 2.7% (1,547) PAGE 4

5 Top 10 Countries UK 580 valid certificates PAGE 5

6 IATF Database KPI

7 UK reporting CB performance 2014 PAGE 7

8 20 day KPI PAGE 8

9 120 day KPI PAGE 9

10 7 day KPI PAGE 10

11 20 day Certificate upload KPI PAGE 11

12 NC analysis

13 Global comparison PAGE 13

14 Witnessed Vs Non-Witnessed PAGE 14

15 Country Comparison Top 10 + UK PAGE 15

16 CB Comparison Jan Oct % Average: 2.94 NCs / Audit 11.38% % Average Average: 5.69 % Major NCs / Total No. of NCs % PAGE 16

17 Witness Audits

18 Witness Audit Status Number: Planned 52 / conducted 47 - Standard 42 of 52 conducted - Follow up 2 of 2 conducted - OEM additional focus 2 of 4 conducted Total nonconformities: 77 Total Major nonconformities: 21 (27%) Total Minor nonconformities: 56 (73%) PAGE 18

19 Nonconformity analysis Rules 3rd Rules 4th On Site Audit 5.8 Impartiality On Site Audit 5. Audit Planning Audit days Eligibility 1.0 Audit Days Audit Report 5.10 Stage Decertification Audit Planning 5.7 Audit Report 5.10 Certificate Issuance Major Minor IATF contractual Req 2.3 Other audits 7.0 Audit Findings 5.9 Eligibility 1.0 Supporting activities Major Minor Audit Report 5.10 other 1 1 Audit Team 5.6 NC Management Certification records PAGE 19

20 Office Assessments

21 Office Assessment Status Number: Planned 13 / Conducted 13 Total nonconformities: 35 - Total Major nonconformities: 13 (37%) - Total Minor nonconformities: 22 (63%) PAGE 21

22 Office Assessment Nonconformity analysis 5.9 Audit Findings Audit Report Decertification Mgt Systems Management Review Int Witness Audit e) Database 2.8 Int Sys Audits 2 2 Major 5.2 Audit Days 7.0 Transfer Audit Minor CPD Audit Cycle Audit Report Cet Issuance Records PAGE 22

23 OEM-directed Witness Audits James Bruin

24 OEM-directed Witness Audits CHRYSLER PARTICIPATION IN TARGETED WITNESS AUDITS SMLC ORIGINAL REQUEST CB IATF_CERT_NO A_TYPE AUDIT_DATE WITNESSED? OBSERVED? MAJOR MINOR NC NC 53031L TPSL NSF-ISR Verification 01/13/14 Y Y 7 3 FAILED 15492E WA request (Bruin) NSF Surveillance 02/04/14 Y Y 8 3 TERMINATED 36670J 2015 UF LRM SGS-ICS Surveillance 02/24/14 Y Y 0 9 ACCEPTABLE 39754D 2015 UF LRM DQS Surveillance 02/26/14 N 65226B TPSL TUEV Manag Surveillance 02/27/14 N 24902G 2015 UF LRM NSF Surveillance 03/19/14 N 52172E 2015 UF LRM ISC Surveillance 03/26/14 N (certificate cancelled) 23087B 2015 UF LRM DQS Surveillance 04/08/14 Y Y 0 5 ACCEPTABLE TPSL NSF Verification 04/11/14 Y Y 0 0 ACCEPTABLE Multi WA request (Evans) BSI Surveillance 04/23/14 N UF LRM DQS Surveillance 05/07/14 Y N 0 8 ACCEPTABLE UF LRM BVC Surveillance 05/08/14 Y Y 0 5 ACCEPTABLE 39754J WA request (English) DQS Surveillance 5/8/2014 Y N 0 5 ACCEPTABLE UF LRM TUEV Manag Surveillance 05/09/14 N 31195N WA request (English) BVC Surveillance 05/16/14 N Multi 2015 UF LRM CERMET -- Transfer 05/23/14 N 38721T 2015 UF LRM BVC Recertification 05/30/14 N 68095J (IAOB inquiry) NSF Verification 06/23/14 Y Y 0 7 ACCEPTABLE UF LRM SGS-ICS Recertification 07/15/14 Y Y 0 8 ACCEPTABLE Multi 2015 UF LRM CERMET -- Initial 08/15/14 N 95042Q 2015 UF LRM BSI -- Initial 08/26/14 Y N 4 6 OPEN CPR escalation ASR Special 08/27/14 Y Y 0 5 ACCEPTABLE LA LRM SAI Global Verification 09/02/14 Y Y 2 4 OPEN Performance Complaint SMITHERS Special 09/15/14 Y Y LA LRM Intertek Verification 09/17/14 N (IAOB inquiry) SAI Global Surveillance 09/22/14 N WA request (Bruin) SAI Global Verification 10/07/14 Y Y UF LRM ASR Surveillance 10/15/14 Y Y UF LRM ASR Special 10/28/14 S S 55553E TPSL Eagle Surveillance 11/17/14 S S 91593E 2015 LA LRM Intertek Surveillance 11/18/14 S E NBH SMITHERS Verification tbd R -- STATUS

25 OEM-directed Witness Audits 2014 Directed Witness Audit program Chrysler decided to request that scheduled audits be witnessed for suppliers considered high risk as a result of: Launch Risk (LRM) Performance Complaints Benefits New vehicle launches supported Cherokee (KL) Challenger (LA) Top Problem Supplier Location New Business Hold Chrysler 200 (UF) Promaster City [port of entry] Nonconformities issued for weaknesses not previously identified Suppliers put on notice about importance of certification Critical nature of audits reinforced with Certification Bodies Audits observed by Supplier Quality personnel Audit results shared with SQ engineers and management

26 OEM-directed Witness Audits Data sharing New Sharepoint site for Chrysler SQ access to TSrelated information

27 OEM-directed Witness Audits Data sharing New report summarizing IATF audit & certificate change activity

28 SMMT IATF Oversight CB Feedback meeting 21 st November 2014 SMMT, the 'S' symbol and the Driving the motor industry brandline are trademarks of SMMT Ltd

29 Adoption of ISO9001:2015?

30 MAQMSR what is this

31 MAQMSR? This is the Minimum Automotive Quality Management System Requirements for sub-tier suppliers which have recently been included in the FORD and Chrysler CSRs. It is available to down load from Base content requirements; 1. Control plans 2. Process approach 3. Performance 4. Internal auditing 5. Control of nonconforming product 6. Part approval 7. Management responsibility PAGE 31

32 FORD PAGE 32

33 Chrysler PAGE 33

34 Chrysler PAGE 34

35 AIAG CQI-19 - Sub-Tier Supplier Management Process Guideline 1. Pre-selection phase 1.1 Define part requirements 1.2 Supplier pre-qualification 1.3 Develop bid list 1.4 Supplier assessment 2. Selection phase 2.1 Review technical capability 2.2 Award business 3. APQP / PPAP Phase 3.1 Begin APQP with supplier 3.2 Complete PPAP / Verify capacity 3.3 Implement production control plan 4. Performance monitoring, development and or escalation phase 4.1 Performance monitoring 4.2 Supplier development PAGE 35

36 AIAG CQI-19 - Appendix D Use of certification bodies and other resources Third-party certification does not replace second-party activities which can better be applied to activities such as APQP and PPAP, however certification body resources can be used to supplement second-party activities and to help drive corrective action needed. Organizations should notify and engage any third-party certification bodies for the purpose of properly identifying and reporting systemic issues causing potential or actual chronic performance problems arising form certified facilities and systems. This means that when a certified company ships nonconforming material to a customer on a chronic basis or where it has caused a disruption the customer should notify the applicable certification body, which should then ensure that the supplier properly determines the root cause(s) and effects appropriate corrective actions. Note that this Guideline is not intended to be an auditable requirement unless this is made a customer specific requirement. PAGE 36

37 Rules 4 th Status

38 New Format for SI & FAQ - format example only below PAGE 38

39 Rules 4 th Sanctioned Interpretations

40 Sanctioned Interpretation Revised SI 4 PAGE 40

41 Sanctioned Interpretation New SI 9 PAGE 41

42 Rules 4 th Sanctioned Interpretations / Frequently Asked Questions After 16 th December

43 New Functionality

44 CB Communique Tracking of nonconformities open but 100% resolved Starting 1 st January 2015 the IATF will modify the IATF Database to allow IATF Certification Bodies to mark those nonconformities in the IATF Database that are considered open but 100% resolved. This functionality will require Certification Bodies to have the information about the nonconformities that are considered open but 100% resolved available at the time when the audit status of the relevant audit is changed to acceptable in the IATF Database. As this new functionality will be implemented starting 2015 it will affect all audits for which the audit result status is changed as of 1 st January A new mandatory field will be added to the Edit Audit template called No. of nonconformities open but 100% resolved. The IATF Certification Body will be required to fill in this mandatory field the number of nonconformities that have been considered open but 100% resolved. If all nonconformities are closed then a 0 needs to be entered. PAGE 44

45 Recording of nonconformities open, but 100% resolved Two new elements will be implemented to enter nonconformities open, but 100% resolved: ❶ ❷ (1) Field "No. of Nonconformities open, but 100% resolved" The total number of nonconformities where a 100% solution has been determined must be entered into this field when the audit result will be changed to "acceptable". (2) Column "100% resolved" The total number of a nonconformity where a 100% solution has been determined must be entered into the field of the relevant ISO/TS clause in the table "Nonconforming ISO/TS- Clauses". Important: the amount of field "No. of Nonconformities open but 100% resolved" must match the total of the fields in column "100% resolved". PAGE 45

46 Recording of nonconformities open, but 100% resolved Data input sequence: (1) Change audit result to "acceptable" The fields in table "Nonconforming ISO/TS-Clauses" will be enabled with this change. (2) Enter the total number of nonconformities where a 100% solution has been determined into the dedicated field. (3) Enter the total number of a nonconformity where a 100% solution has been determined into the field of the relevant ISO/TS clause. Once entered the relevant clause will be displayed in the list of the selected clauses. PAGE 46

47 Recording of nonconformities open, but 100% resolved Report template Oversight version The current report will be extended by (1) The default field "Number of NCs 100% resolved" This field will be displayed in the online version of the report and appears also in the download file. new new (2) The additional filter "Report Variant" The option Add data for "NCs 100% resolved" to the report creates the "extended" report version and contains in total 409 columns. The columns containing the number of "nonconformities open but 100% resolved" for the ISO/TS clause will be added to the present download version of the report. The option Audits containing "NCs 100% resolved" only creates the limited" report version and contains in total 147 columns. Only the columns containing the number of "nonconformities open but 100% resolved" for the ISO/TS clause will be added to the online version of the report. PAGE 47

48 Recording of nonconformities open, but 100% resolved Available report variants: My Audit Non-conformities - online version OO New field My Audit Non-conformities - download version OO "standard" columns: 278 New field 131 clauses 262 columns PAGE 48

49 Recording of nonconformities open, but 100% resolved Available report variants: My Audit Non-conformities - download version OO "limited" columns: 147 New field My Audit Non-conformities - download version OO "extended" columns: 409 New field 131 clauses 262 columns 131 clauses 131 columns PAGE 49

50 Recording of nonconformities open, but 100% resolved Report template CB version The current report will be extended by new (1) The default field "Number of NCs 100% resolved" This field will be displayed in the online version of the report and appears also in the download file. At the moment the configuration didn t contain any filter to add the number of "nonconformities open but 100% resolved" per ISO/TS clause to the download version of the report. Variants like the OO versions are not foreseen at present. PAGE 50

51 Recording of nonconformities open, but 100% resolved Available report variants: My Audit Non-conformities - desktop version CB New field: My Audit Non-conformities - download version CB - columns: 278 New field: PAGE 51

52 Recording of nonconformities open, but 100% resolved The following additional characteristic values can be calculated with a minimum of effort: Audits "acceptable containing NCs 100% resolved Audits "acceptable containing only NCs 100% resolved Total number of nonconformities 100% resolved Ratio PAGE 52

53 New Functionality

54 PAGE 54

55 PAGE 55

56 PAGE 56

57 Supplier COFOR Code Structure PAGE 57

58 Support definitions

59 Current Support Function drop down list PAGE 59

60 Alternatives / New PAGE 60

61 ADP Status

62 Results of NC Management / PA Training As of 30 October 2014, 957 have completed both training modules Per CB Communiqué , auditors have until 31 December 2014 to complete the training modules (both) we are tracking monthly reminders will be sent out at the -45, -15 day mark again (duplicating the process utilized last time for the Rules 4 Training/Quiz); both the auditor(s) and their CB(s) are notified PAGE 62

63 CB Communique IATF ADP Training Module updates mandatory completion All active auditors and non-auditors enrolled in the IATF ADP are required to take both the revised IATF ADP training modules: Process Approach and NC Management. Auditors and non-auditors who have been active in the IATF ADP on or after 1 st May 2014 are required to complete the two training modules by 31 st December 2014, both training modules will be undertaken in a nonproctored environment. These training modules are worth the following hours of structured CPD (continual personal development) and auditors may only take credit for these structured CPD hours once they are completed. Please note that counting the approved CPD hours for these revised training modules multiple years is not allowed. Process Approach= 6 structured hours NC Management = 4 structured hours PAGE 63

64 CB Communique Auditors who do not complete the revised Process Approach and NC Management modules by 31 st December 2014, 12 midnight GMT time, will be deactivated January 2015 and unable to participate in ISO/TS audits in January and February The reactivation of these auditor s credentials, thus their ability to work as an ISO/TS auditor, will not occur before 1 st March 2015 and will only occur through the following process: Payment in the IATF ADP a reactivation fee - $150 USD Completion of the IATF ADP training modules Process Approach and NC Management prior to 1 st March 2015 (NOTE: Training modules are to be completed after ADP reactivation in January/February timeframe.) PAGE 64

65 CB Communique All IATF ADP CB Admins may track their auditor s performance to this important training requirement by following the simple procedure below: IATF ADP CB Admin contact logs into the IATF ADP Admin Site: Then click on the Advanced Search link and select 2014 Training Update Completed. This will allow IATF ADP CB Admins to see all the auditors who have completed the required CB Communique training to date. Alternatively, CB Admins may also select 2014 Training Update Pending. The auditors who are in the pending status have not completed BOTH training modules to date. Credit is only given after BOTH training modules have been successfully completed. PAGE 65

66 CB Communique PAGE 66

67 CB Communique IATF ADP testing requirements for all Free Ticket candidates (nonauditor CB veto power, internal systems auditor, etc.) All free ticket candidates are required to take the initial Knowledge and Application Assessment within one (1) year of entry into the IATF ADP. If this timing is not met, free ticket candidates may be deactivated in the IATF ADP system. Deactivation in the IATF ADP system would then also invalidate the free ticket candidate s approved role of CB veto power, internal systems auditor, etc., as they would no longer meet the Rules 4 th requirements (see Rules 4 th edition, section 4.6). PAGE 67

68 IATF OEM Scorecard Training Modules As of 30 October 2014, we have Chrysler, Ford, and GM materials drafted and in the ADP (training and quiz) PSA, VW, BMW, and FIAT have committed to submit materials by 31 January 2015 as well Daimler will not submit anything No response from Renault to date Timeline adjusted for translation to flow into Q1 2015, thus launch mid-july 2015 PAGE 68

69 Witness Audits New report Format

70 Witness Audit Report New format developed by IATF sub group Implemented globally 1 st November 2014 Standardized content with detailed guidance for the witness auditor Concise reporting to allow CBs to quickly understand strengths and weaknesses PAGE 70

71 Witness Audit Report Timings From report issue date 15 days 20 days 60 days 90 days 15 day acknowledgement (Huddle) 20 day correction (for Major) 60 day submission (root cause, corrective action and verification) 90 day closure PAGE 71

72 Huddle Task management through Huddle Click on Tasks Click here to expand task PAGE 72

73 Expanded task view Brief description of task. This description is updated as the report progresses. Tasks updated by Oversight Task status updated by person assigned to task Due date set by originator of the task (Oversight) Task linked to attachment from witness audit file. Once added, this attachment will always link to the latest version of the report. Assignee responsible for entering start date and changing status to in progress Assignee determined by originator of task (Oversight). This can be more than one person. PAGE 73

74 Next Steps Office assessment template will be updated to reflect this new style IATF are looking to develop some audit management software to support the witness audit process from planning and preparation through to closure PAGE 74

75 Any other business

76 Special audits and database entry It may become necessary for the certification body to conduct audits of certified clients to investigate performance complaints (see section 8.1 a/b) in response to changes to the client s quality management system (see section 3.2), significant changes at the client s site, or as a result of a suspended certificate (see section 8.3), to verify the effective implementation of identified corrective actions for major nonconformities (see section ), or to verify the effective implementation of identified corrective actions for nonconformities considered, open, but 100% resolved (see section c). SI 4 A special audit and the reason for the special audit shall be entered into the IATF database within twenty (20) calendar days from the closing meeting of the audit. PAGE 76

77 Letter of Conformance Rules 4 th 5.4 g) upgrade to ISO/TS16949 from a letter of conformance (see section 514). The certification body shall be the same for the existing letter of conformance and for the new ISO/TS16949 certification the certification process shall proceed by the same certification body with an initial audit (stage 1 readiness review and stage 2) with a maximum reduction of 50% possible in audit days for the stage 2 audit. PAGE 77

78 Letter of Conformance Option 1: The CB calculates the audit days in line with 5.2, applying the various discounts (ISO:9001, VDA 6.1, non design responsible, etc) in line with 5.4. This would establish the audit day duration applied during the Letter of Conformance audit. That audit day duration (calculated in line with 5.2/5.4 and recalculated before the certification audit) can then be reduced by a maximum of 50% when the client moves from a Letter of Conformance to certification (assuming the requirements are met (within 12 months etc). (the theory being that a stage 2 audit had already been undertaken recently and the certification visit can be of reduced duration). Option 2: The other interpretation is that when the CB calculates the audit days, they can apply a maximum discount of 50% (as detailed already in 5.4), although they don t refer back to 5.4. PAGE 78

79 Nonconformity Management - discussion PAGE 79

80 Training

81 New Auditor 1 st 5 th December 2014: Bangkok, Thailand 19 th 23 rd January 2015: IF Office, Birmingham 22 nd 26 th June 2015: Bangkok, Thailand 20 th 24 th July 2015: IF Office, Birmingham 7 th 11 th December 2015: Bangkok, Thailand Current Auditor ADP Proctored sessions, Birmingham th January 10 th April 3 rd July 16 th October PAGE 81

82 2015 meeting schedule

83 New Auditor PAGE 83

84 THANK YOU IATF Oversight Office 2680 Kings Court, The Crescent, Birmingham Business Park, Birmingham, B37 7YE