2013 IACBA Workshop
Auditing OEM Customer Specific
Requirements under ISO/TS 16949
2013 IACBA Workshop
• Ford, GM and Chrysler sent representatives to
this years IACBA workshop.
• Each representative provided a presentation on
the approach their OEM wants to see from
Certification Body auditors when performing
Customer Specific Requirement audit under
ISO/TS 16949.
• It did not appear that the OEM representatives
were going to allow copies of their presentation
to be distributed, so I am sending out these notes
from the presentations for our ISO/TS auditors.
2013 IACBA Workshop
Ford Motor Company – Russ Hopkins
• The Ford Customer Specific Requirements
(CSR) were updated in June, 2013. They can
be accessed through the AIAG or IAOB web
sites.
• The highlighted changes or focus items from
this presentation deal with:
– CSR Changes
– Focus on Supplier Metrics
2013 IACBA Workshop
Ford CSR – PPAP
• Sub-Tier supplier management now includes
obtaining PPAP submission from sub-tiers in
support of a Tier One supplier submission.
• PPAP requirements have been extended to
include Ford Service (FCSD) parts.
• Two new forms have been added or updated:
• APQP Evidence Workbook
• Special Characteristics Approval
2013 IACBA Workshop
• Safety Characteristics – Approval requirements
have been added to PPAP that control these
special characteristics regardless of the tier at
which they are manufactured.
• Items have been added to PPAP to define certain
specific considerations for:
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Electrical Component Design Records
Service Part Details
Branding Requirements
Heat Treating
2013 IACBA Workshop
• Updated requirements for Gage R&R for
attribute gages have been added to PPAP
• Initial process capability and Final process
capability are now required to be expressed in
PpK.
• Process capability results are to be recorded
on the Evidence Workbook.
2013 IACBA Workshop
• In addition to the changes noted, there will be
additional sub-tier requirements which will be
issued through Ford CSR.
• These will cover the areas of:
– APQP Approval for sub-tier submissions
– Tracking of sub-tier performance to timing for
PPAP submission
– Tracking of sub-tier changes
– Reporting requirements for these items
2013 IACBA Workshop
Ford CSR – ISO/TS 16949
All Ford suppliers should be aware of these updates
and changes and should have incorporated them into
their Ford requirement system.
• Supplier access to the Ford Team Center has been
authorized. All suppliers can now access engineering
specifications.
• A report change has been made to re-define capacity
calculations.
• Proto-type tooling disposition requirements have been
added.
2013 IACBA Workshop
• Tier One PPAP submission must now include
evidence that all sub-tier PPAP submissions
have been approved.
• The rules for suspension of a certificate have
been clarified.
• Requirements for special process assessments
(may use the AIAG CQI forms) have been
added.
2013 IACBA Workshop
• The direction for auditors when performing ISO/TS 16949 audits with ASR
clients who are part of the Ford supply chain would include:
NOTE: SIM system information should be part of every ISO/TS 16949 audit as it represents Ford
communication with its suppliers. (ISO/TS 16949 7.2.3 & 7.2.3.1)
– Review the process for APQP and PPAP submission to ensure that all sub-tier
suppliers are submitting PPAP documentation and that evidence of approval of
sub-tier PPAP exists.
– Review the Ford service requirements with the client and determine if the
FCSD parts have PPAP documentation and approval.
– Review the client’s records for any of the following and determine if they have
identified all Ford requirements:
• Electrical Component Design Records
• Service Part Details
• Branding Requirements
• Heat Treating
2013 IACBA Workshop
– Review audit records to determine if special process audits are being
performed as required.
– Review gage R&R records to determine if there are any attribute gages in
use. If there are, do results meet all Ford requirements.
– Review process capability records and verify that:
• Initial capability has been recorded
• Final capability has been recorded
• Both capability measures are at or above Ford requirements
• Both capability measures are recorded in PpK
Are all Ford CSR being addressed in the client’s
QMS?
2013 IACBA Workshop
GM – Joe Bransky
• There is a planned update to the CSR for GM later this year.
• Currently, GM is asking that the Certification Bodies to help
them bring about the kind of improvements that ISO/TS
16949 was supposed to obtain.
• The guiding principles for GM in this effort are:
– ISO/TS 16949 is a robust Quality Standard.
– Customer specifics should be kept to a minimum.
– Requirements (CSR and ISO/TS) should be cascaded
throughout the supply chain.
– When CSR are issued, the GM template should be
consistently applied.
2013 IACBA Workshop
GM CSR – CB Notification
• The important requirements of quality concerns issued
by GM should be understood by auditors. They are:
– CS I, part specific actions including containment and
internal inspection. Formal corrective action may or may
not be required.
– CS II, part specific actions including containment and 2nd
party inspection. Formal corrective action is required.
– New Business Hold (NBH), issued after the identification of
unacceptable risk with a supplier. Requires an approved
action plan and regular updates with the GM SQA.
2013 IACBA Workshop
• When GM has notified a certification body
that one of their clients has be issued a CS II or
NBH there is an anticipation by GM that
certain actions will be taken by the CB.
– Begin the suspension process for the ISO/TS
16949 certification
– Require an on-site verification audit to determine
if exit criteria have been met
– Evaluate corrective actions taken to verify
effectiveness
2013 IACBA Workshop
GM CSR – 6 Panel Reporting
• All GM suppliers have access to 6 Panel Reports that
are specific to their quality and delivery metrics.
• The 6 Panel contains data, pulled directly from the GM
Global Database, on:
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Part Rejection Report (PRR) activity
Current PPM levels
Discrepant Part Disposition
GM Plant Disruptions
Stock-out / Downtime
Sub-Tier PRR activity
2013 IACBA Workshop
• It is important to remember that all suppliers
to GM will have direct access to the 6 Panel
Report through the GM Supplier Portal.
• The only exception to this rule would be a
supplier that has not been issued a PRR in the
last 12 months. These suppliers do not have a
6 Panel Report.
• Auditors cannot access the portal, but all GM
suppliers can.
2013 IACBA Workshop
• One key to the whole improvement piece, in
GM’s view, is the application of the same type of
data collected and communicated to the Tier One
suppliers throughout the supply chain.
• The first step in encouraging this is the addition
of sub-tier PRR reporting to the 6 Panel.
• Tier One suppliers are expected to take an active
role with their sub-tier suppliers in addressing
PRR and other GM concerns.
2013 IACBA Workshop
GM CSR – Special Processes
• Special Process auditing requirements have
been flowed down to all GM suppliers as of
June, 2013.
• The audit forms/reports applicable to these
audits are:
– CQI 9 Heat Treating
– CQI 11 Plating
– CQI 12 Coating
2013 IACBA Workshop
• All suppliers should be performing Special
Process audits, as required.
• These Special Process audit requirements
apply to sub-tier suppliers as well.
• This includes those sub-tiers that provide a
service involving one or more of these Special
Processes to the Tier One and those sub-tiers
that provide parts that have been subjected to
a Special Process.
2013 IACBA Workshop
• The Special Process audits do not currently
apply to Soldering (CQI 17) and Welding (CQI
15).
• However, an auditor should ask about these
two Special Processes because GM Supplier
Quality can request that they be audited as
part of the purchase agreement.
2013 IACBA Workshop
• The direction for auditors when performing
ISO/TS 16949 audits with ASR clients who are
part of the GM supply chain would include:
– Review of the actual 6 Panel report on the GM portal
to confirm that the client has the capability to access
the report.
– Review of the 6 Panel data to evaluate any activity or
spikes.
– Review of the sub-tier PRR section of the 6 Panel to
evaluate actions taken where sub-tier PRR activity has
been reported.
2013 IACBA Workshop
– Review of the audit records to establish that the client
is performing all required special process audits.
– Review of audit records from sub-tier suppliers to
establish that all required special process audits are
being performed.
– Review purchasing documents from GM to determine
if Soldering or Welding special process audits have
been required by GM Supplier Quality.
Are all GM CSR being addressed in the client’s QMS?
2013 IACBA Workshop
Chrysler – James Bruin
• There have not been any changes to the
Chrysler CSR.
• There may be an update in 2014 when
Chrysler has completed some of the project
work they are doing with Fiat to merge their
two systems.
2013 IACBA Workshop
Chrysler CSR – External Balanced Scorecard
• The External Balanced Scorecard is the
communication tool Chrysler uses with the
supply chain.
• The evaluation criteria that appears on the
Balanced Scorecard is drawn from several
sources within Chrysler.
• Sourcing decisions are made on the basis of
the Scorecard and several other criteria.
2013 IACBA Workshop
• Esupplierconnect has replaced Covisint as the
portal through which suppliers are accessing the
Scorecard and other Chrysler information.
• The Scorecard defines supplier performance
using 5 Value Drivers:
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Quality
Delivery
Warranty
Cost
Partnership
2013 IACBA Workshop
Chrysler CSR – Supplier Bid List
• The Supplier Bid List draws data directly from the
Chrysler system and summarizes in in categories.
• The Bid List will show the current data related to
supplier performance for the passed month.
• The scores noted will adjust over a six month rolling
average and may reflect a status that is related to an
issue that has been resolved.
• Supplier performance is indicated as scores and will
also be highlighted as Green-Yellow-Red to indicate the
status of the supplier against Chrysler required score
targets.
2013 IACBA Workshop
• The Bid List is sent to any Certification Body who is
indicated as the CB of record for a Chrysler supplier.
• The anticipation is that the CB will take action to
investigate any supplier that shows a Yellow or Red
status on the list.
• Actions might include:
– Investigation with the client to determine what actions are
being taken.
– Contact with the Chrysler SQE to determine the current
status of actions.
– A special visit audit to confirm effectiveness of supplier
actions
2013 IACBA Workshop
NOTE:
• ASR receives the Bid List from Chrysler monthly.
• The ASR Quality Manager reviews the list and identifies any of
the ASR clients that are in a Yellow or Red status.
• The ASR Quality Manager will contact these clients and
determine the nature and extent of the issue(s) driving the
status.
• In those cases where (1) there will be an open issue(s) at the
time of the next scheduled ASR audit, (2) there has been a clear
escalation of the issue(s) or (3) the extent or nature of the
issue(s) remains severe; the ASR Quality Manager will contact
the assigned auditor and will provide information on the client’s
issue(s) and status as input to the audit planning.
• When warranted by the nature of the client’s issue(s) or status a
Special Audit may be scheduled by the ASR Quality Manager.
2013 IACBA Workshop
• The direction for auditors when performing ISO/TS 16949
audits with clients who are part of the Chrysler supply
chain would include:
– Ensure that the client regularly accesses the Chrysler portal and
is aware of their status on the External Balanced Score Card.
– Where a Quality or Delivery issue is identified on the Score Card
confirm that corrective action has been initiated and is effective.
– When notified by ASR Corporate of a Yellow or Red status for a
client you are about to audit, investigate the reason for the
status and all actions that have been initiated.
Are all Chrysler CSR being addressed in the client’s
QMS?