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Understanding TS 16949:2002

Start with the anger, fear, and frustration of the Big Three that despite QS they are still getting bad parts. Honda and Toyota never were big into QS and they get better parts and have fewer problems. It couldn't be the fault of the Big Three, so it has to be the fault of the standard, the registrars, and especially the parts suppliers, those lazy, cheating, so-and-sos!

I can imagine their conversation. "This time we will put BIG teeth into the d__med standard! We will make 'em ship us good parts. Or else..."

One way to get better control was to take registrar and auditor control away from the national bodies such as the RAB (Registrar Accreditation Bureau). So they set up the IAOB International Automotive Oversight Bureau) under the auspices of the IATF (International Automotive Task Force). The IAOB now accredits registrars to work on TS, and controls the official training and certification for auditors. Both systems have caused howls from just about everyone but the Big Three.

They beat into the auditors and registrars around the head and ears to make sure that they conduct audits to catch any shoddy practices or merchandise, and ensure that registered companies ship only stellar parts.

A typical audit goes like this (it is a process audit by the way):

The first things you will be asked is which of the Big Three you supply (or their spin-off wanna-bes such as Delphi or Vistion).
Then they ask about your score (returns, problems, issues, late delivery and whatever).
Then they ask to see the contracts, POs, quotes, and other contract documents
Then they ask to see all the other relevant documents mentioned on the POs (even the fine print on the back) or in the supplier programs, or on the customer web site.
They look at the evidence that you have done everything mentioned in any of the documents or references, and write you up if you do not have the evidence or a letter saying you are exempted from the requirement. Given the number of things on a GM or Ford web site, this can be big, and can be pretty silly.
Then they ask for the APQP and especially current up-to-date PPAP for the parts
Then they go out and verify that what you are doing (on all shifts) is exactly what you had approved in the PPAP.
Then they look at Cpk and internal failures (scrap and rework) as signs that you CAN make bad parts, they want perfection.
They look at the evidence that you irrevocably corrected any past problems.

In other words, they are doing what they were told/trained to do: make sure you are making and shipping only good parts, and toeing the line to meet all the requirements ever published by the customer.

With this cheerful mental image, Midwest professionals go over each word of the standard to ensure that you understand what it says and how it will be audited. They will review the some of your records to see if you are likely to run into trouble where you think you have the bases covered.

QS-9000 to TS Upgrade

Here we use our side-by-side comparison of the QS and TS language, showing the differences, and highlighting the bombs:

4.1.1 Quality Policy The supplier’s management with executive responsibility shall define and document its policy for quality, including objectives for quality.	5.3 Quality policy Top management shall ensure the quality policy c) provides a framework for establishing and reviewing quality objectives,
And its commitment to quality	b) includes a commitment to comply with requirements and continually improve the effectiveness of the quality management system,
The quality policy shall be relevant to the supplier’s organizational goals and the expectations and needs of its customers.	a) is appropriate to the purpose of the organization,
The supplier shall ensure that this policy is understood, implemented, and maintained at all levels of the organization.	d) is communicated and understood within the organization, and
	e) is reviewed for continuing suitability.

During class we look at your existing procedures to help you decide what to do with them, if anything. We tailor a new Quality Manual to include your procedures and operations, and offer the necessary and useful forms (such as a new management review form) and procedure templates to fill gaps. You and the other guides need to attend the whole session, but the other Champions only need be learn their part. We end up providing you with a detailed to-do list including all the issues we discuss in class.

Sometime during the class days we schedule time for a management overview so that the decision-makers can understand want is new, what is going to happen, and how they can use the upgrade in standards to make more money. Many of the changes to the ISO 9001:2000 are specifically designed to make the standard more consistent with the needs of business to be financially successful, but those aspects are often missed and under-used.

Managers will receive copies of the PowerPoints to help them remember and focus on their opportunities, especially relating to the quality policy and objectives. We offer an optional management workshop (2, 4, and 6 hour versions) to grow their understanding, increase their participation, and improve the integration of the quality system and the business system.

By the way, this time The standard will be world-wide. The Big Three revised the language of the standard (slightly) to meet European wording, and "forced?" the Europeans to go along. They invited the Asians to join, but no takers. Despite claims of Asian company support for TS, there are no signators or copyright owners listed on the document or the web site, as there are Europeans like Fiat Volkswagen.

From the IAOB Web Site about the IATF

"The IATF is an "ad hoc" group of automotive manufacturers and their respective trade associations, formed to provide improved quality products to automotive customers worldwide. Specifically, the purposes for which the IATF was established are:

To develop a consensus regarding international fundamental quality system requirements, primarily for the participating companies’ direct suppliers of production materials, product or service parts or finishing services (e.g. heat treating, painting and plating). These requirements will also be available for other interested parties in the automotive industry.
To develop policies and procedures for the common IATF third party registration scheme to ensure consistency worldwide.
To provide appropriate training to support ISO/TS 16949 requirements and the IATF registration scheme.
To establish formal liaisons with appropriate bodies to support IATF objectives.

IATF members include the following vehicle manufacturers: BMW, DaimlerChrysler, Fiat, Ford Motor Company, General Motors (including Opel Vauxhall), PSA Peugeot-Citroen, Renault SA, Volkswagen and their respective trade associations - AIAG (U.S.), ANFIA (Italy), FIEV (France), SMMT (U.K.) AND VDA (Germany)."

For More Information Contact: tony@midwestquality.com or 800 464-9008