IATF Ford Motor Company

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1 IATF Ford Motor Company

2 Requirement to Certify to IATF Sue Leone, Executive Director Ford Supplier Technical Assistance Requires tier 1 suppliers to become certified to IATF to meet Q1 requirements. Letter dated 22 February 2017 Copyright 2017 Ford Motor Company

3 IATF Ford Customer Specifics Ford released CSR for IATF March 2017, effective 1 May 2017 A cascade letter explains the changes from the ISO/TS at a high level Both are available on IATF web site Copyright 2017 Ford Motor Company

4 IATF Ford Customer Specifics Key areas with Ford customer specifics Certification to IATF required to achieve and maintain Q1 Corporate Responsibility aligns with Ford Terms and Conditions Contingency plans include Supply Risk Management Operating System Plant planning includes Capacity Planning before equipment installation Special Characteristics are approved by Ford Sub-tier suppliers not certified to ISO/TS or IATF use Minimum Automotive Quality Management System Requirements for Sub-tier Suppliers (MAQMSR) Software developers are assessed to Automotive SPICE Suppliers with Q1 Revoked status must notify their Certification Bodies Copyright 2017 Ford Motor Company

5 Transition to IATF Steps to a successful transition to IATF Confirm dates for transition audit with your Certification Body Develop a work plan back from the date of the transition audit Review the requirements and provide feedback as soon as possible if there are concerns Allow enough time after the transition audit to address non conformances Copyright 2017 Ford Motor Company

6 Transition to IATF Where to provide feedback if challenges to transition are observed Suppliers: provide feedback through your National Associations (AIAG being one of them) Certification Bodies: provide feedback through your Oversight Offices OEMs: provide feedback through your representative on the IATF Copyright 2017 Ford Motor Company

7 Transition to IATF Resources Go to the IATF web site for the latest news, interpretations and updates Copyright 2017 Ford Motor Company

8 Transition to IATF Status IATF data reports the following: 51 weeks remaining for the transition 202 suppliers to Ford transitioned Over 3500 certifications remaining 70 transition audits for Ford suppliers need to take place each week before September 2018 With planning this is possible for all OEMs Globally over 1200 audits need to take place each week, covering all sites Less than 1 audit per week per auditor with planning, this is possible Please do not wait to confirm your transition audit date Copyright 2017 Ford Motor Company

9 Transition to IATF Status Questions? Copyright 2017 Ford Motor Company

10 Aaron A. Dodak Global Supplier Quality Manager

11 General Motors Supplier Data Top 10 QMS Failures (BIQS Elements)

12 General Motors IAOB Supplier Incentive Based on Supplier data and similar data from other OEM s, the IAOB Steering Committee and Board of Directors recognized the need to create a workshop to both help develop suppliers while addressing significant issues that impacted their site. The IAOB Board of Directors approved funding this new workshop.

13 Intervention Workshop The purpose is to support the development and validation of a workshop approach to address current needs in the automotive industry. Automotive suppliers are ISO/TS or IATF compliant. Yet, non-conforming errors still occur. WHY? Is class room training effective?

14 Intervention Workshop The Core Focus of the Workshop: To perform a reverse PFMEA of the issue by taking the plant team and walking the factory line, verifying PFMEA is correct and up-to-date. The team will check the PCP to ensure it matches the PFMEA; ensuring the PCP frequency of checks is adequate to keep a nonconforming part from leaving the plant. The team will then verify Standard Work is correct and clear on how to perform the PCP checks. This Workshop takes a hands-on approach to addressing a real problem at the source. The activity teaches the team how to become effective problem solvers.

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17 General Motors What Can Be Accomplished by Creating a Successful Partnership with Safety and Quality as the Primary Focus?

18 AIAG Quality Summit IATF 16949:2016 Update Automotive QMS Transition September 19, International Automotive Oversight Bureau Ms. Cherie Reiche, IAOB

19 % Certificates by Region Valid Certificates per Region [%] 68.2% 0.8% 2.2% 9.2% 2.6% 17.0% Africa Asia Pacific Europe Middle East North America South America International Automotive Oversight Bureau 19

20 Supplier Certification Progress International Automotive Oversight Bureau 20 Slide courtesy of VDA QMC

21 IATF Progress As of 31 st August 2017: 3,172 completed audits to IATF As of 31 st August, total NCs issued = 16,916 (average 5.33 ncs per audit) International Automotive Oversight Bureau

22 Top 10 Major NCs August Internal auditor competency Total productive maintenance Contingency plans (ISO) Nonconformity and corrective action Problem solving Customer-specific requirements (ISO) Control of production and service provision Product safety International Automotive Oversight Bureau 22

23 Top 10 minor NCs August Total productive maintenance Control plan (ISO) Control of production and service provision Contingency plans Special characteristics Standardised work operator instructions and visual standards Measurement systems analysis Verification of job setups International Automotive Oversight Bureau 23

24 Actions to Ensure Success Global Oversight Conducting monthly reviews with all 43 contracted certification bodies to ensure: CBs/Clients are scheduling transition audits CBs have the necessary resources (auditors) Forecasting audit schedule / auditor resources Contingency plans where either timing or resources cannot be achieved International Automotive Oversight Bureau

25 Actions to Ensure Success IATF Members Conducted Stakeholder Feedback session in Oberursel, Germany (near Frankfurt) 13 th Sept All IATF contracted CBs were represented Selection of certified suppliers represented All Oversight Offices supported All IATF OEMs and IATF National Associations supported International Automotive Oversight Bureau 25

26 Subscribe to the IATF website International Automotive Oversight Bureau 26

27 Common questions Must we use both ISO 9001:2015 and IATF 16949:2016 when conducting audits? ANSWER: Yes, as it states in the IATF Foreword Automotive QMS Standard, IATF is not a standalone standard, it must be used in conjunction with ISO 9001: International Automotive Oversight Bureau

28 Common questions Will the IATF be granting waivers for those organizations who cannot meet the Transition Plan timing? ANSWER: No, from 1 st October 2017 onward, all audits are required to be conducted to IATF There are no plans to approve/grant waivers ISO/TS certificates are not valid past their expiry or 14 th September 2018, whichever occurs first International Automotive Oversight Bureau

29 Common questions What about competency for internal auditors and second-party auditors? Do they have to all take an IATF-sanctioned lead auditor training course? ANSWER: No. Organizations are responsible for ensuring key personnel, including their auditors, are properly trained and competent. The IATF supports the use of IATF-recognized training providers; however, the IATF does NOT mandate the use of a lead auditor training course for all auditors in the organization. Organizations are still allowed to have key personnel International Automotive Oversight Bureau trained and certified as lead auditors, and then using

30 Common questions What is the goal of ? Do all organizations supplying automotive product have to be IATF certified? ANSWER: As stated in , the ultimate objective is to have IATF certification; however, the IATF recognizes that for various reasons, that is not feasible for all organizations. At a minimum, the expectation is for organizations to be certified to ISO 9001:2015, unless otherwise authorized International Automotive Oversight Bureau by the organization s customer(s)

31 Common questions Do all of my support locations need to be audited to IATF before the mfg locations can transition to IATF 16949? ANSWER: No. Please see the IATF Transition Strategy document. The Transition Strategy supplements Rules 5 th Edition (and any SIs or FAQs related to Rules): International Automotive Oversight Bureau

32 Next steps You need to have these critical things ISO 9001:2015 IATF 16949:2016 Rules 5 Transition Strategy Applicable CSRs For the Standards and Rules, please see: International Automotive Oversight Bureau

33 International Automotive Oversight Bureau Thank You!

34 IATF Transition Case Study Stadco Ltd Mike Khanna and Matt Gill, Magna International

35 Stadco History 1812

36 Stadco History 1812 John Hall

37 Stadco History

38 Stadco History

39 Stadco Locations

40 Stadco Intranet Based Quality System

41 Timeline Oct 1 st 2016 Jan 17 Today Jan 18 Read & Gap Analysis Documentation updates Deadline Sept 14 th 2018 Training Group Function Audit Castle Bromwich Plant Audit Powys Plant Audit Shrewsbury Plant Audit Telford Plant Audit

42 Transition Steps Taken Group Senior Management Engagement Group role assigned as primary lead Plant stakeholder engagement Outline overall timing to include; Group Plants 3 rd parties; Training, CB, Suppliers

43 Transition Steps Taken Gather data access to resources AIAG, IATF, SMMT, Magna, BSi Select project tools Plexus Gap Analysis Spreadsheet ; c.196 unique line items to be answered inc. Annexes Action Tracker Subdivided ownerships Determine responsibility split for Group & Plant Address group tasks with group functional leads Head Office audited 1st Prepare interpretation for Plant leads Standardise best practice Use our 1 st Plant as the Pilot and test our approach & refine

44 Transition Steps Taken

45 Plant Approach Details Issue Group Gap Analysis findings and verify the potential Plant gaps Allow Plant the time to digest the combined analysis findings and interpretations Return & agree action plan with Plant Management team Set priorities, factor in system updates and evidence of process taking place Agree timing to meet deadlines, inc. readiness review

46 Plant Approach Details Set cadence & fix in diaries Increasing in frequency towards the deadline Monthly, Fortnightly, Weekly Meeting style Action review inc. escalation Interpretation review Readiness preparation Carry out IATF Audits

47 Trip Hazards

48 Trip Hazards Requirement Potential Gap What we did Increased management of suppliers Enhanced audit framework inc. competence, scorecards Updated current procedure with increased risk assessment, lead auditor training and scorecards. Contingency Plan Testing Inadequate test approach Schedule IATF Desk Top role play and feedback into recovery plan.

49 Trip Hazards Requirement Potential Gap What we did Risk Management Lack of evidence that risk assessment is undertaken and reacted to. Building on current foundation and integrated approach, clarified the risk tools used and their link to improvement plans. Temporary Change Of Process Not a coherent process. Establish current response, define process, link to similar activities like; PFMEA, Primary & Secondary Controls, Rework & Repair, Shutdown Verification.

50 Trip Hazards Requirement Potential Gap What we did Repair & Rework Not a coherent process. Work to OEM R&R method as default. Create centralised best practice log to define process and approval. Shutdown Verification Not common across group. Establish best practice from OEM s and apply risk based logic at all plants.

51 The Audits OK Audit Minor Major

52 The Audits Readiness Audit Focused on the changes to a fixed Certification Body checklist. Supply advanced data Prove you meet all requirements, > Checklist; Gap Analysis Are we ready?

53 The Audits Transition audit Office based elements were more IATF change orientated Production area elements were more familiar in focus

54 The Result

55 Key Recommendations TRAIN EARLY

56 Key Recommendations ENGAGE LEADERSHIP

57 Key Recommendations START NOW!!

58 Questions please

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