Information on ISO/TS 16949:2009

1. ISO/TS 16949:2002 1
Awareness Training
1.0 Basic Details:
• .Full name : ISO/TS/ 16949:2002 ( Second edition )
TS means: Technical Specification.
• Released by ISO (International Organization for
Standardization)
in the year 2002 . ( First edition was released in the year 1999)
• Prepared by IATF with JAMA (International Automotive Task
force and Japanese Automotive Manufacturers Association)
2.0 Three Goals of TS:
1. Continual Improvement
2. Emphasizing defect Prevention
3. Reduction of variation and waste across the supplier
chain.
3.0 .Eight Management Principles deployed through
TS :
1.Customer Focus
2.Leadership
3.Involvement of people
4.Process approach
5.Systems Approach to management
6.Continual Improvement
7.Factual basis of decision making
8.Mutually beneficial Supplier
relationship
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com

2. ISO/TS 16949:2002 2
Awareness Training
4.0 IMPORTANT TERMS/ABBREVIATIONS:
S.No Acronym Full form
01 APQP ADVANCED PRODUCT QUALITY PLANNING
02 PAP PART APPROVAL PROCESS
03 FMEA FAILURE MODES & EFFECTS ANALYSIS
04 SPC STATISTICAL PROCESS CONTROL
05 MSA MEASUREMENTS SYSTEM ANALYSIS
06 RPN RISK PRIORITY NUMBER
07 CPM CRITICAL PATH METHOD
08 MTBF MEAN TIME BETWEEN FAILURES
09 MTTR MEAN TIME TO REPAIR
10 PSW PART SUBMISSION WARRANT
11 CSR CUSTOMER SPECIFIC REQUIREMENTS
12 ITR INVENTORY TURN OVER RATIO
13 GRR GAGE REPEATABILITY & REPRODUCIBILITY
14 CFT CROSS FUNCTIONAL TEAM
15 MDT MULTI-DISCIPLINARY TEAM
16 ISO INTERNATIONAL ORGANISATION FOR
STANDARDISATION
17 IATF INTERNATIONAL AUTOMOTIVE TASK FORCE
18 JAMA JAPANESE AUTOMOTIVE MANUFACTURERS
ASSOCIATION
19 SOP STANDARD OPERATING PROCEDURES
20 GD & T GEOMETRIC DIMENSIONING & TOLERANCING
21 IQA INTERNAL QUALITY AUDIT
22 NCR NON CONFORMITY REPORT
23 OEE OVERALL EQUIPMENT EFFECTIVENESS
24 WP WORK PROCEDURE
25 WI WORK INSTRUCTION
26 nDC NUMBER OF DISTINCT CATEGORIES
27 TS TECHNICAL SPECIFICATION
28 CA &PA CORRECTIVE ACTION & PREVENTIVE ACTIONS
29 QMS QUALITY MANAGEMENT SYSTEM
30 EMS ENVIRONMENTAL MANAGEMENT SYSTEM
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com

3. ISO/TS 16949:2002 3
Awareness Training
31 MR MANAGEMENT REPRESENTATTIVE
32 MRM MANAGEMENT REVIEW MEETING
33 IQA INTERNAL QUALITY AUDIT
34 PDCA PLAN DO CHECK ACT
5.0 PROCESS APPROACH:
What is a process?
A “Process” can be defined as a “Set of interrelated or interacting
activities, which transforms inputs into outputs”. These activities require
allocation of resources such as people and materials. Figure 1 shows the
generic process.
A major advantage of the process approach, when compared to other
approaches, is in the management and control of the interactions between
these processes and the interfaces between the VARIOUS FUNCTIONS of
organization.
EFFECTIVENESS
OF PROCESS =
Ability to achieve
desired results
Input Interrelated or interacting Output
Requirements Specified activities and control Requirements Satisfied
(Includes resources) methods (Result of a process)
Monitoring and Measuring EFFICIENCY OF
PROCESS =
Results achieved
vs. resources used
Figure 1. Generic process.
Inputs and intended outputs may be tangible (such as equipment, materials
or components) or intangible (such as energy or information). Outputs can
also be unintended; such as waste or pollution.
Each process has customers and other interested parties (who may be
either internal or external to the organization) that are affected by the
process and who define the required outputs according to their needs and
expectations.
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com

4. ISO/TS 16949:2002 4
Awareness Training
A system should be used to gather data, which can be analyzed to
provide information about process performance and to determine the
need for corrective action or improvement.
All processes should be aligned with the objectives of the organization and
be designed to add value, relative to the scope and complexity of the
organization.
Process effectiveness and efficiency can be assessed through internal or
external review processes.
The performance of an organization can be improved through the use
of the process approach. The processes are managed as a system,
by creating and understanding a network of the processes and their
interactions.
The outputs from one process may be inputs to other processes and
interlinked into the overall network or system .
Outputs from
Outputs from
other processes
other processes
Inputs Outputs
Outputs
to A from D
PROCESS A Inputs to B from B Inputs to D
PROCESS B PROCESS D
Outputs
from A
Outputs
Inputs to C from C
PROCESS C
Example of a generic process sequence
Management Processes
I O
Measurement, Analysis, and Improvement
Process Design
I O
I
I Product Design Production O
I O I O
Project Planning
O
I O
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , I O
94 239 72 351
Nasik 422 009 Resource Processes
business.diagnostics@gmail.com

5. ISO/TS 16949:2002 5
Awareness Training
6.0 Turtle Charts:
Process Approach is deployed in the organization through the use of
Turtle-charts.
WITH
WHO ?
WHAT ?
INPUTS PROCESS OUTPUTS
HOW TO
HOW ? MEASURE ?
Just think:
1.You are responsible to which process in your organization
?
2.what kind of turtle chart will be formed for this
process ?
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com

6. ISO/TS 16949:2002 6
Awareness Training
7.0. What is FMEA ?
Failure Modes & Effects Analysis
Preventive Method to understand “potential” problems that can happen to a
product and its likely effect on the subsequent operations or the
customer.
Analysis of What is a Design FMEA Process Important
failure modes failure ? Not FMEA words
and their Failure: applicable to •RPN
effects. •Not able to us since we Here process
•Severity
achieve what are not means the
Analysis of is required involved in manufacturing •Occurrence
types of the design process. Detection
failures and
•Non of the
conforming
•Prevention
what will product.
Controls
happen •Not as per ( drawings
because of specification given to us •Detection
failures. s by the Controls
•Not as customer..
we only
decided
manufacture
as per the
drawing )
•Severity • Prevention •Detection •
Intensity of Controls Controls
failure How is it
noticed on
•Occurrence How the How the
shop floor ?
Probability or defect is defect is
prevented detected For example:
chance that
this failure from when ever it
Receiving,
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com

7. ISO/TS 16949:2002 7
Awareness Training
will happen happening ? happens ? In-process,
•Detection Set up, Final
How easy it is Any mistake Inspection
to detect this –proofing
defect done on this
equipment ?
• Severity Occurrence Detection Higher is the
Intensity What is the What is the RPN
of the chance or chance that Higher is the
effect of likelihood the failure need to take
the failure. that such shall get actions
Whether type of detected ? So….do the
effects is failure will •Easy to ranking of
major or occur.? detect ? FMEA as per
minor ? •It is the the RPN nos
Determine
•Difficult to
probability
the ranking find out ?
that a said
on a scale cause will •Determine
of 1 to 10. happen. the ranking
•Determine on a scale of
1: effect the ranking 1 to 10.
quite on a scale of
negligible 1 to 10.
10: effect
very •1: Easy to
•1: less
serious.
probable to detect
happen •10:Difficult
•10: good to detect.
chance of
happening.
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com

8. ISO/TS 16949:2002 8
Awareness Training
8.0 Any audit leads to improvement only.
Suggestions for the Auditee: (the person who is going to be
audited ):
A. Must have the following with you at the time of audit:
1. The turtle chart for the process for which you
are getting audited.
2. The work Instructions of your function.
3. The quality records (Properly completed with
date, signature )
B. Remember that the auditor is going to follow the
process –approach.
So better first cross check yourself whether you have
the right answers for upstream and down stream
processes. ( i.e. towards the input side and the output
side of your process.)
C. TS means understanding & implementing the TS
requirements and also the customer requirements .
So, better study the same before auditing.
D. The loop must be closed. ( Plan-Do-Check-Act )
E. In TS audit ,auditor can verify the compliance
through any of the following methods:
a. Through records and documents.
b. By observing the work( actual process)
c. Through cross checking with other
information.
F. If there are any NC’s to your function in the internal
audit, you must know the corrective actions taken by
you.
G. It is expected that you know the customer complaints
and actions taken on the same.
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com

9. ISO/TS 16949:2002 9
Awareness Training
H. You are also expected to have complete data
regarding the quality objectives of your function .
( Target/Actual status)
9.0 Types of audit Non Conformities( NC or NCR)
Major NC Minor NC
System does not exist. There are isolated cases of
non compliance to the
There is no awareness about the system.
work instructions of own area.
System not implemented at all. Not affecting the product
quality.
More number of minor non
conformities under the same
clause.
10.0 General Suggestions:
1. It is the system audit and not your audit. Any non-
conformity raised is towards the system and not to auditee
in specific.
2. Auditor’s main role is to verify the conformance of the
system and not finding out your faults/mistakes.
3. It is always better to be open than to hide any thing
from the auditor.
4. Please be specific in answering the questions.
5. If you have not understood the question correctly,
please request the auditor to repeat the question.
6. Please do not start telling “stories” to the auditors.
7. Be just a good human being.
8. Auditor is always happy when you show him the
objective evidence (proof) of what you are saying or
claiming what you are doing.
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com

10. ISO/TS 16949:2002 10
Awareness Training
9. Keep a writing pad and pen handy for writing any
suggestions given by the auditor.
10.If possible , switch off your mobile when your audit
starts.
11. If auditor asks some information which is not in your
area of responsibility, better tell him/her accordingly
rather than giving a wrong answer.
11.0 Suggestions for preparation for the external
audit:
1. Do cross auditing( inter-functional) with one of your
colleagues.
2. Carry out a self-examination by the following method:
A .Take the process manual
B. Verify the records as mentioned in the “list of
records”
C. Verify all documents as mentioned in the “list
of documents”
D. Ensure that on the shop floor:
a. All control plans/process sheets/work
instructions/safety instructions are properly
displayed
b. All fire-extinguishers are in ok condition.
c. rejection is identified and kept with
proper identification.
d. No parts in the gang-ways(aisles)
e. shop floor persons are neat/clean.
f. Quality policy is displayed and known to
people.
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com

11. ISO/TS 16949:2002 11
Awareness Training
Revision # 1 Dt: 13.08.07.
Business Diagnostics, Course Facilitator: Santosh Kulkarni
102,Manohar Nagar , 94 239 72 351
Nasik 422 009
business.diagnostics@gmail.com