Value of IATF 16949 Certification – What results

reveal about your organization (Breakout Session)

 IATF 16949 Certification Scheme

29% increase in total

number of certificates
in past 7 years
IATF 16949 Certification Scheme
 IATF 16949 Certification Scheme

Purchase at: Available for free:

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New APQP & Control Plan –
What’s In It For Me?
 What is APQP
• Advanced Product Quality Planning is a
methodology that originated in the
automotive industry to ensure the
development and production of high-
quality products that meet customer
requirements and expectations.

• APQP includes a series of steps and

tools to ensure that all necessary
planning and preparations are made
before mass production.

• The goal of APQP is to prevent quality

problems, improve overall customer
satisfaction, and drive continuous
improvement.
Benefits of APQP?
• Improved product quality

• Enhanced customer satisfaction

• Increased efficiency

• Reduced costs

• Improved supplier relations

• Better risk management

• Improved process control

• Promotes early identification of required changes

• Provides a quality product on time at the lowest cost

 Why the need for APQP Update
• Incorporation of Lessons Learned from
issues with escapes and delays during
new product program launches

• “New technology" suppliers enabling

acceleration to ACE (Autonomous,
Connected, Electric) may not be familiar
with APQP and as a result may lack
experience in automotive product
quality planning fundamentals
 Changes to APQP
• Removed Control Plan content into stand alone
document
• Added Sourcing section and Sourcing Checklist
• Added Change Management section and
Change Management Checklist
 Changes to APQP
• Added section for APQP Program Metrics,
including Example in Appendix C.
• Added section for Risk Assessment Mitigation
Plan
• Added "Part Traceability“ content
Changes to APQP
• New Gated Management Section
– Suggested documentation checklists for
each “gate” review
– Aligned to typical Program milestones
– Supports expectation for “gate review” in
1.14 Leadership Support
– Includes review of Supplier (sub-tier)
APQP activity, not just Organization’s
 What is a Control Plan
• Control plans provide a written summary
description of the systems used in
minimizing process and product variation.
• The Control Plans supports the Product
Quality Planning Cycle
– Early in the product life cycle its primary purpose is to
document and communicate the initial plan for process and
product control
– Subsequently, it guides manufacturing in how to control the
process and ensure product quality
• The control plan is an integral part of an
overall quality process and is to be utilized as
a living document, evolving to incorporate
improvements and lessons learned as they
occur
 What are the benefits of Control Plan?
• Guides manufacturing in how to control the process and ensure product
quality. During regular production runs, the control plan provides the process
monitoring and control methods that will be used to control product and/or
process characteristics.
• Provides the organization the baseline to evaluate output, review the control
plan and make appropriate changes based on lessons learned and quality
performance data.
• When utilized as “Family Control Plan” or “Foundation Control Plan”, allows
more efficient new product development and launch.
 Why the need for Control Plan Update
• Control plan continues to be an ongoing point of audit non-
conformances and is consistently in both the top ten major
and minor non-conformances as identified by the
International Automotive Oversight Bureau (IAOB).
• Incorporate Lessons Learned from escapes during both
Product Launch and Mass Production.
• Allowances and considerations for new and/or highly
automated manufacturing processes.
• Opportunity to harmonize Customer Specific Requirements
of Ford, GM and Stellantis.
• Separating Control Plan from APQP
– Provides more detailed and thorough guidance to all users for
development, maintenance and utilization of Control Plan
– Allows more frequent change of Control Plan to reflect continuing
evolution of automotive product and processes
 Control Plan Manual Overview
Section Key Content Expansion from APQP/CP v2

0. Introduction Clarify link to APQP processes; Living Document

1. Requirements/Guidelines Clarify Requirements (topics from lessons learned and

Customer Specific Requirements)
2. Control Plan Development Detailed guidance how to develop, not just form fields

3. Control Plan Phases Addition of “Safe Launch” requirement

4. Effective Use of CP Guidance based on practices of excellent organizations

App A: CP Examples Table for Process Dependent considerations; General to

illustrate key requirements/expectations
App B: Forms/Checklists Updated based on changes in Chapters 1-3
 Control Plan Key Content/Changes
Chapter 1: Requirements & Guidelines
• Details Requirements and Guidelines for 12 topics based on past problems/opportunities
• Key examples:
o Special Characteristics
▪ Allow use of “correlation matrix” (correlate organization symbols to customer's)
▪ Customer may also designate "key" or "critical" characteristics for special handling
o Pass-Through Characteristics
▪ Organization must have a process to identify and ensure adequate control of PTC
throughout supply chain, and must communicate control methods to customer
▪ Recommended CQI-19 PTC Matrix to communicate control methods to customer
o Directed Supply
▪ Organization must get necessary information from Supplier to develop Organization's
control plan unless otherwise specified by mutually signed agreement (MPA, etc.)
 Control Plan Key Content/Changes
Chapter 2: Developing Control Plan
• Process Flow (how to develop, phases)
• Previously just described “Form Field content”, now
includes description of how to obtain information and
some minimum expectations, including:
• Frequency – if NOT 100%, must be volume-based
and support containment
• Reaction Plan – clarified expectation to include
contain suspect product, stop process from
creating more suspect product, steps to bring
process back to control.
• Reaction Plan – Requires inclusion of
“Owner/Responsible” for the Reaction, or
reference to detailed instruction document
 Control Plan Key Content/Changes
Chapter 3: Control Plan Stages
• Addition of “Safe Launch” requirements
• Typical Application (figure 3.1)
• Pre-Launch: Customer may require during Pilot
Stage and continued into launch; how to document
• Production: Start of Production WILL include Safe
Launch; Must establish judgment criteria to exit
Safe Launch - typically 90 days no problems to
customer and no problems identified by Safe
Launch additional/enhanced controls/containment
• Production Control Plan is a living document, and should
be updated with lessons learned and other continuous
improvement data sources
 Control Plan Key Content/Changes
Chapter 4: Effective Use of Control Plans
• Consideration points for effective use of QMS and other elements related to Control Plan
implementation
• For a several topics, describes:
• Definition/Key Concept
• Why the topic is important
• What to do and how to do it
• Topics Include:
• Reverse PFMEA
• Using Software to Develop and Manage Control Plan
• Layered Process Audit as Control Plan Verification
• Control Plans in Highly Automated Processes
• Using Family/Foundation Control Plans and FMEAs
• Control of Storage and Handling Related Risks
• Abnormality Management related to Control Plans
Fast Feedback Team
• Implemented “Fast Feedback” Team concept
• Accelerated development cycle (quicker/earlier stakeholder
input)
• Cross-section of AIAG membership representing major
commodities with global insight (North America, EU and China)
• Key Topics Impacted
• APQP:
– Gated Management
– Traceability Thank You FFT!!
– Checklists (best practices)
• Control Plan:
– Special Characteristics
– Pass-Through Characteristics
– Reaction Plan details
– Directed Supply
 General Motors
• First, at GM our basic thoughts were that the current
APQP/CP manual was fundamentally sound.
• The current APQP and Control Plan manual second
edition was published in 2008, a lot has transpired in 16
years, like autonomous driving , electrification expanded
use of software, so it was time for an update.
 General Motors
• When we looked at the Control Plan we made the decision that it
needed to be its own manual as we felt it was important enough and
the driving force behind protecting the customer and deliver the
highest quality process controls.
• Decoupling the two documents also made sense so timely updates to
either can be made as systems evolve, especially where applications of
CP are changing to meet demands imposed by higher automation,
autonomous driving, and electrification.
 General Motors
• Most importantly, we have tried to give more clarity around the
guidelines and requirements within the new manuals to avoid pitfalls
from known risk factors by incorporating lessons learned from past
projects and problems.
• Whether we work on advance technologies for EV/Autonomous or ICE
vehicles we feel these manuals deliver to our suppliers the tools
necessary to meet the needs of all OEM’s.
• Sector specific guidance is included for more accurate application of
the methods by significantly different organizations and to aid in third-
party verification audits.
 General Motors

∙ Implementation at General Motors will be 6 months after

publication of the manual
 Ford
• Our products continue to add more and more new
technologies and features. Advanced Quality Planning is
essential to the success of these new technologies and
features.
• At Ford, Quality is our top priority. The greatest and most
cost-effective impact to quality is in the development stage
which is why APQP is so important. Updating APQP and
control plan manuals with the latest lessons learned and best
practices will help in achieving flawless launches.
 Ford
• The industry has evolved at a rapid pace since the last update
to the APQP manual, and while the current manual has held
up well through this evolution, we felt it was time to update
the manual to include best practices and lessons learned over
the decade and a half.
 NEW APQP & CP Webinar
• What you need to know to be Ready!
– Hearing first-hand from the AIAG Facilitator
• Tuesday, December 5, 2023
• Registration Opens: 10:45am EST
• Webinar: 11:00am – Noon,
• https://www.aiag.org/store/events/details?Event
Code=E23APQP
 Sign up for Pre-Sale
Be the first to get notified when the Pre-Sale Starts
• QR Code available in our AIAG Booth
Thank you
Rules 6th Edition
Overview of Changes that Impact Certified
Organizations
 Agenda
1. Rules 6th project timing
2. Effective date
3. Publication
4. Stakeholder feedback
5. Key changes
 Rules 6th Project Timeline
• Initial draft completed by June 2023
• Stakeholder feedback event conducted in March 2023 and June 2023, including
sharing of the initial draft with certified organizations
• Disposition of stakeholder feedback is in-process and additional changes to Rules
6th draft is expected
• Final draft approved by the IATF in December 2023
• Saleable version in all languages by 31 March 2024
 Rules 6th Effective Date

The Rules 6th effective date should be

announced by year end
 Rules 6th Publication
Purchase Rules 6th Edition through AIAG

https://www.iatfglobaloversight.org/iatf-publications
Rules 6th Stakeholder Feedback
 Rules 6th Key Changes
Extended manufacturing sites (Section 1.1)
• Must be ten (10) miles and no more than 60-minute drive from the main manufacturing
site which will ensure a consistent application across all IATF-recognized certification
bodies and support the IATF’s concept of an extended manufacturing site
• Allowance for support personnel to be located at the extended manufacturing site to be
more reflective of how companies operate
 Rules 6th Key Changes
Audit cycle (Section 5.1.1)
• Removed the six (6) and nine (9) month surveillance intervals since it had limited use and
added complexity to the audit day calculations
• Removed certificate suspension for a late surveillance audit and instead allow
surveillance audits to be conducted up to three (3) months late without suspension
• In the event surveillance audit timing or recertification audit timing is exceeded, the CB
will cancel the client’s certificate
 Rules 6th Key Changes
Determining Audit Duration (Sections 5.2 and 5.4)
• Added specific timing for the verification of corrective actions for nonconformities to
ensure the CB auditor has the appropriate amount of time for effective verification
activities:
– 1 hour - 1.5 hours for each major
– 30 minutes - 1 hour for each minor

• Permitted reduction for a corporate scheme is now 15% (regardless of the number of
sites) to ensure CB auditors have sufficient time to conduct an effective audit
• Reduced the maximum possible audit day reduction from 50% to 30% to ensure enough
time for an effective audit
 Rules 6th Key Changes
Audit planning / Audit plan (Sections 5.7.1 & 5.7.2)
• Organizations must confirm audit dates no less than ninety (90) calendar days prior to
the start date of the next regular audit to ensure CB auditor resource availability,
excludes special audits
• Organizations must provide pre audit planning information no less than thirty (30)
calendar days prior to the start date of the audit which allows the CB auditor to create an
audit plan and provide it to the organization for their coordination
• In the event an organization does not provide audit planning information in the required
timing, the CB may delay or cancel the audit, which may result in the organization’s loss
of certification
 Rules 6th Key Changes
Nonconformity Management (Section 5.11)
• Organizations must submit a response for a major nonconformity in fifteen (15)
calendar days, instead of twenty (20) calendar days, including the containment action
and evidence of the containment’s effectiveness
• The CB has thirty (30) calendar days from the audit closing meeting date to accept the
organization's response or resolve any outstanding issues
• Failure to submit a response to any nonconformity within the required timing requires
the CB to withdraw the certificate
 Rules 6th Key Changes
Nonconformity Management – 100% resolved (Section 5.11)
• A one-time special audit to verify the effectiveness of the corrective action(s) that were
100% resolved must be conducted no less than ninety (90) days prior to the next regular
audit
• Thirty (30) days prior to the one-time special audit, the organization must submit
evidence that the corrective action effectiveness has been internally verified
 Rules 6th Key Changes
Remote Auditing (Section 7.3)
• The remote auditing method can be used to audit employees normally working
remotely and for surveillance audits of some remote support functions – refer to Annex
4
• Remote auditing is not permitted for manufacturing sites as the technology is not yet
reliable globally for effective audits of the manufacturing floor
 Rules 6th Key Changes
Decertification Process (Section 8.0)
• Now only two inputs to the decertification process:
– Performance complaints
– Nonconformities issued during surveillance, recertification, or special audits
• All performance complaints, including IATF OEM special status conditions, will be
received through the IATF Complaint Management System (IATF CMS)
• “Long lead” corrective action items for performance complaints require another special
audit to verify effective implementation of actions no more than 180 calendar days from
the date the CB’s received the complaint
Questions