Rough Transition to IATF 16949

Globally, there are over 68,000 organizations certified to ISO/TS 16949:2009 that will need to undergo a transition audit to IATF 16949:2016. As of April 2017, 181 of these audits have been completed this year, resulting in an average of 5.3 nonconformities and nearly one major nonconformity (0.73) per audit. There is a lot we can analyze and learn from these audits. What areas are receiving nonconformities?

What surprises lie in these nonconformities? What are 3rd party auditors finding/not finding? The list of nonconformities can be used as a preventive measure to ensure key registrar nonconformities are addressed before your transition audit. Omnex has performed a large number of gap analysis audits for our customers and will compare our findings to the list of registrar nonconformities. What were Omnex’s top findings? How many of them still remain? Why are companies still receiving major nonconformities for “Auditor Competencies” and “CSRs” when that was one of the top findings in Omnex’s gap analyses? These are just some of the questions we will explore.

Top five Nonconformities

The top five nonconformities overall are “Total Productive Maintenance” (48), “Control Plan” (38), “Contingency Plans” (37), “Control of Production Service Provision” (26), and “Internal Auditor Competency” (23).

The two biggest surprises shown in this list are Total Productive Maintenance (TPM) and Control of Production and Service Provision. The requirements for Total Productive Maintenance (8.5.1.5 of IATF 16949) have increased significantly from those of ISO/TS 16949.We can infer that when organizations are implementing IATF 16949, they have so much to update in other areas that maintenance is not getting the attention it needs. Despite the many additional requirements found in IATF 16949, the 3rd Party auditors are not overlooking the expanded requirements for Total Productive Maintenance. Total Productive Maintenance has also made it to the top five list of major nonconformities, showing that it is indeed an area that needs the attention of the IATF 16949 implementation champion. Similarly, Control of Production and Service Provision (8.5.1 of IATF 16949) has requirements for “special processes” and “implementation of actions to prevent human error.” Control of Production and Service Provision is showing the fourth most nonconformities of all areas in IATF 16949.

Based on the IAOB data, the top five major nonconformities are CustomerSpecific Requirements (CSRs) (7), Internal Auditor Competency (7), Quality Management System Audit (7), Total Productive Maintenance (6), and Management Review Inputs (6). Omnex gap analyses are also finding major nonconformities in CSRs, Internal Auditor Competency, Quality Management System Audits and Management Review Inputs. Management Review Inputs have not changed drastically enough in IATF 16949 to be resulting in so many major nonconformities.

Omnex gap analyses have found many of the majors are the result of a variety of issues with the ISO/TS 16949 management reviews.

The issues involved in the nonconformities and the implementation of these requirements in a manner that reduces the risk of being issued a nonconformity have been discussed in many of our IATF 16949 webinars available at Omnex.com. These webinars also cover many key preventive issues, in addition to other issues that have not yet been added to the list of 3rd party auditor nonconformities. Omnex’s goal is to provide professional insights to assist you in achieving a successful IATF 16949 implementation in your organization. If you have any questions on how Omnex can help your organziation with your IATF transition, write us at info@omnex.com

Chad Kymal is the CTO and founder of Omnex Inc., an international consulting and training organization headquartered in the United States. After graduating from the General Motors Institute, Chad spent a number of years working at General Motors and KPMG before founding Omnex Inc. in 1986. Over the course of Chad’s successful career, he has served on the Malcolm Baldrige Board of Examiners and has received numerous quality achievement awards, including the Quality Professional of the Year award by the American Society for Quality (ASQ) Automotive Division in 2005.In addition to his bachelor’s degree from GMI, Chad holds both a master’s degree in industrial and operations engineering from the University of Michigan and an MBA Cum Laude from the University of Michigan. He is a member of Tau Beta Pi.

Chad both developed and teaches auditor training for ISO 9001, ISO 14001, and OHSAS 18001 / ISO 45001, as well as an Integrated Management Systems Lead Auditor training course where all three standards are combined in a single audit. Chad is the founder of AQSR, a global registrar that routinely provided integrated audits in QMS, EMS, and OHSMS. Chad is also on the ISO/TC 176, ISO/TC 207, PC283 committees for ISO 9001:2015 (Quality Management), ISO 14001:2015 ( Environmental Management) and ISO 45001 (Health and Safety Management Systems.

Omnex has been working in the Automotive industry for 30 years and Omnex principals been active in writing different automotive standards including QS 9000, ISO/TS 16949, Semiconductor Supplement, APQP, FMEA and Core Tools. Chad conducted the first world-wide witness audit for QS 9000 a predecessor to IATF 16949. He is the author of seven books and more than 100 papers including several on integrated management systems.

Chad is currently working on books for ISO 14001 and IATF 16949.

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