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he final draft of ISO Technical Specification (TS) 16949:2002 is now available. Although its circulation is limited to a small group within the international quality management standards community, it is a sign that ISO/TS 16949:2002, Quality management systemsAutomotive suppliersParticular requirements for the application of ISO 9001:2000, will be soon released to the larger public. Voting on TS 16949:2002 will conclude in December 2002, with the second editions release expected by March 1, 2002. What is still missing are the customer-specific requirements of the original equipment manufacturers (OEMs) for the use of TS 16949:2002. These requirements, usually available on an OEMs web site and accessible by its suppliers, must be used by a supplier to achieve quality management system (QMS) conformance with TS 16949:2002 so as to satisfy the requirements of a particular existing or potential OEM customer (e.g., BMW,
ber 2003 as a contractual requirement (for the latest on the Big Threes registration requirements, see the box below). 2. Suppliers will want an ISO 9001:2000-registered QMS to gain the improvements in the 2000 edition and satisfy requirements of nonautomotive customers. As we stated in A Plan for the Transition From QS-9000 to TS 16949:2002 (THE OUTLOOK, August 2001), the second in our series of guidance articles on preparing for and making the transition, TS 16949:2002 is more influenced by ISO 9001:2000s new structure than any new automotive-based requirements change. For the most part, the first edition of TS 16949 has been faithfully mapped into the ISO 9001:2000 framework to create TS 16949:2002 (for more information, see The Impact of ISO 9001:2000 on QS-9000 and ISO/TS 16949, THE OUTLOOK, May 2001, the first article in this series).
umors have it that DaimlerChrysler, Ford and GM will require their tier 1 suppliers to become registered to TS 16949, preferably the second edition. Also, QS-9000 is expected to be extended to 2005 for those suppliers that have contracts only with domestic US facilities of the Big Three. Suppliers that are not tier 1 and do not want the ISO 9001:2000/TS 16949:2002 registration could technically stay QS-9000-registered for the time being. In other words, QS-9000 will not be revised to align with ISO 9001:2000. Also, per the International Accreditation Forum (IAF), all certificates of registration to ISO 9001/2/3:1994including sector-specific ones involving QS-9000 (and thus ISO 9001/2:1994) will have to be upgraded to ISO 9001:2000 by December 15, 2003. 1994-based certificates will not be considered valid after that date (except by the Big Three, as noted).
Omnex, Inc.
734-761-4940 4 www.omnex.com
ISO 9001:2000 & Deployed Objectives addressing TS 16949:1999 customer expectations ISO 9001:2000 Creation of internal communication processes suitable to organization
5.6, Management Review ISO 9001:2000 & Revision of previous management TS16949:1999 review process (TS adds additional items to be reviewed) 6.1, Resource Management ISO 9001:2000 Provision of Resources 6.2, Human Resources (particularly 6.2.2.3 on empowerment) 7.0, Product Realization 7.1.4, Change Control 7.3, Design and Development 7.4, Purchasing Establishment of a resource allocation process
ISO 9001:2000 & Provision of job competency, on-the-job TS 16949:1999 training and employee motivation (6.2.2.3 and 6.2.2.4) ISO 9001:2000 New (actually Fords Q-101) New Documents for effective control of all processes in process map Minor change for most suppliers Inclusion of design and development of processes, not just product (note required development and use of FMEAs) Inclusion of service suppliers in coverage; ISO 9001:2000 registration of suppliers Customer rating for quality and delivery insufficient; monitoring of customer perceptions of quality Manufacturing process and product audits
New
8.2.1, Monitoring and ISO 9001:2000 MeasurementCustomer Satisfaction 8.2.2, Internal Audit TS 16949:1999
8.2.3, Monitoring and ISO 9001:2000 & Process studies on manufacturing proMeasurement of Processes TS 16949:1999 cesses. Measurement of all processes in process map 8.4, Analysis of Data ISO 9001:2000 Increased scope from QS-9000
Reprinted with permission from THE INFORMED OUTLOOK November 2001 issues
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Volume 6, Number 11
them. Furthermore, TS 16949 has expanded the applicability of Clause 7.3, Design and Development, to both product and process design by including 7.3.2.2, Manufacturing Process Design Input, and 7.3.3.2, Manufacturing Process Design Output. No organization implementing TS 16949:2002 can exclude 7.3, Design and Development, because every product and service parts supplier has production processes that need to be designed and developed using the QMS. The other paradigm is that an organization does not have to control its suppliers processes unless the customer requires it. The last paragraph of 4.1 in ISO 9001:2000 and TS 16949:2002 clearly states that, when the organization chooses to outsource any process that affects product conformity with requirements, the organization shall ensure control over such processes. Subclause 4.6.2, Evaluation of Subcontractors, in ISO 9001:1994 and QS-9000 does require an organization to exercise control over its suppliers, but only to meet customer requirements for subcontractors and to the extent necessary to ensure supplier-provided product meets specifications relative to the organizations product. With TS 16949:2002, an organization will need to include outsourced processes within its process map and QMS whenever a supplier can affect the organizations product, including heat treating or plating or any component of an assembly manufactured by that supplier. A process map is a flowchart that maps out all the processes and their elements that define what your organization does, including all its key activities and more. When creating a process map, an organization will need to go beyond the clauses and subclauses of TS 16949:2002 to truly meet its requirements for an effective QMS. Telltale signs to auditors that a QMS is not truly effective is a process map that only includes QMS elements related to the standard being audited against. Inherently, a process focus is different from a departmental focus in that a process may move through every department within an organization. The antithesis of the process approach promoted by ISO 9001:2000 and TS 16949:2002 is the compliancedriven approach of many organizations, which implemented quality system procedures based solely upon elements of QS-9000 without any thought to creating systems that actually support and enhance the processes within their operations. Our organization recommends that your organization study four types of processes for inclusion in the process map: q TS 16949 Processes q Product Realization Processes q Support Processes q Business Processes. TS 16949:2002 processes are those that inherently fulfill the requirements of the TS. Product Realization Processes include product ideation, R&D, marketing, design and development all the way through to delivery of product and post-delivery services. Support Processes aid the overall organization, including operations such as training, purchasing and document control. Business Processes are those that differentiate your organization from its competitor and help fulfill customer needs and expectations. Business Processes are the most important for the success of a business. Of course, there is overlap in the four types of processes, as shown in Figure 2 on page 4. By definition, Product Realization and Support Processes are exclusive. In other words, a process can either be a support process or a product realization
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process, while TS 16949 Processes and Business Processes can be both product realization and support processes. After studying the different processes, your organization can create a process map that identifies its processes. The process map also can show the sequence and interaction of these processes. Two diagrams presenting complete process maps appeared as Figure 1 in both previous articles in this series.
7.4, Purchasing
The purchasing requirements have not changed very much from QS-9000. Organizations will need to continue following their purchase order process (7.4.2, Purchasing Information), supplier development process (7.4.1.2, Supplier Quality Management System Development) and receiving inspection process (7.4.3, Verification of Purchased Product). What has changed is the scope of supplier development and the new requirement for supplier development that involves a registration deadline. With TS 16949:2002, there will also be no leeway on what constitutes a purchased product. NOTE 1 to 7.4.1, Purchasing Process, defines purchased products as all products and services that affect customer requirements. Organizations will be required to carefully study their supplier lists and add in all suppliers that affect customer needs and expectations, per the previously mentioned ISO 9000:2000 definition of requirement. As for registration requirements, 7.4.1.2, Supplier Quality Management System Development, requires an organization conforming to TS 16949:2002 to require its suppliers to register to ISO 9001:2000 by an accredited third-party certification body. NOTE 1 to 7.4.1.2 requires that suppliers comply with ISO 9001:2000 by December 15, 2003the IAFs date for termination of the transition to ISO 9001:2000. This, of course, is the first step in the ultimate OEM goal of driving the manufacturing supply base to TS 16949, Second Edition. Although NOTE 2 indicates that a customer may mandate alternative requirements for subcontractors, this registration requirement is causing conWeb Site: HTTP :// WWW .INFORM INTL . COM
Support Processes
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cern among QS-9000-registered organizations, many of which do not feel they have the clout to impose registration requirements on their supply base. Our organization has seen the effects of quality system requirements on client supply bases since Fords Q-101 and GMs Targets for Excellence. Nevertheless, we encourage your organization to move forward as follows: 1. Determine your product and service supply base (i.e., expand your key supplier lists). 2. Determine the criteria and deadlines for supplier development requirements, including ISO 9001:2000 (December 15, 2003) and TS 16949:2002 (subsequently). 3. Announce the requirements and criteria to your supply base. 4. Have evidence that you are trying to comply with TS 16949:2002s intent. Organizations typically mention all the exceptions in justifying why they cannot implement supplier development (i.e., suppliers are unwilling, too small or strategic). However, our organization recommends that its clients formulate their strategies around the 95% of their supply base that is likely to cooperate, rather than around the exceptions. If you follow this strategy, both your customer and your registrars auditor(s) are likely to understand the odd exceptions. Since no one is indispensable, the odd exceptions will lose out in the long-term by failing to adopt an effective way to manage their operations. We have just explored 3 of the 15 significant challenges we believe will face QS-9000-registered organizations transitioning to TS 16949:2002. There is a lot of work ahead for companies that likely have only a little more than two years remaining before an OEM will be expecting registration to this second edition. Organizations need to make their plans to transition to the second edition of TS 16949 today. How much work your organization has ahead of it depends on the quality of its QS-9000-registered quality system. To help you gain a better understanding of what the transition will likely involve for your organization, we have identified an anonymous organization willing to serve as a case study for transitioning to TS 16949:2000.
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Europe. What then is the definition of top management? After the poor showing on the audit, QSTS contacted our organization. We collectively decided that it did not make sense for them to pursue ISO 9001:2000 and TS 16949:1999, but that they should instead pursue ISO 9001:2000 and TS 16949:2002, which had just become available in final draft form. The implementation is in its infancy, and the scoping of the implementation is the first challenge. The second challenge will be the requirements of ISO 9001:2000 and TS 16949:2002, especially Management Review, linkage of processes and purchasing. This case study will be expanded in upcoming articles that will explore the remaining 12 challenges of TS 16949:2002 and their impact on QSTS. For now, any organization would be wise to focus on the three clauses of TS 16949:2002 discussed above, since they are the starting point for effective conformance with ISO 9001:2000 and the second edition of TS 16949. ### Chad Kymal is Chief Executive Officer of Omnex, Inc., an international consulting, training and software organization specializing in business quality improvement methodologies. Omnex has worked with hundreds of organizations to meet the requirements of ISO 9001/2/3, QS-9000 and ISO/TS 16949 worldwide and obtain registration. He assists organizations worldwide in his capacity as a consultant and trainer. Mr. Kymal recently served on the Malcolm Baldrige National Quality Award Board of Examiners, has a BSME from General Motors Institute and has an MS in Industrial Operations Engineering and an MBA from the University of Michigan. He can be contacted by e-mail (ckymal@omnex.com).For more information, visit www.omnex.com. David Watkins is President of Omnex, Inc., and is a senior trainer/consultant. He has a wide range of international experience focused on enhancing the ability of organizations to create value for their customers and stockholders and integrating QMSs and other management systems to enhance performance. Mr. Watkins can be contacted by email (dwatkins@omecconsultants.com).
ABOUT OMNEX
MNEX Inc., along with its affiliates is an international consulting, training and software organization, which from the outset has specialized in business quality improvement methodologies. Among our family of companies are OMNEX-which provides training, OMNEX Management and Engineering Consultants for quality systems implementations and OMNEX Systems, LLC. OMNEX, as a leader in Quality Systems consulting, training and software, is uniquely qualified to assist companies in increasing their market share. We provide leading Quality focused consulting and training to the automotive, truck, semiconductor and service industries. Headquartered in Ann Arbor, Michigan, OMNEX & its affiliates also operate in: q Shanghai, China q Bangkok, Thailand q Malaysia q Toronto, Canada q Philippines q Sao Paulo, Brazil q Europe q Argentina and we have targeted Korea and Japan q Mexico for future expansions. q Venezuela q Chennai, India The OMNEX Mission The OMNEX mission has been to transfer our extensive knowledge and experience in the industry to the advantage of our clients who can utilize quality systems in their work environment. OMNEX offers unparalleled commitment to meeting the quality related training and consulting requirements of our global customers.
OMNEX implements quality improvement methodologies not only for manufacturing organizations but also for improving quality of service for organizations like hospitals, transportation companies & construction companies. It is encouraging for us that the service quality for these organizations has improved their performance indices over their competitors dramatically. OMNEX in the Competitive World Thousands of companies worldwide who have aggressively sought a competitive advantage have implemented the OMNEX approach to quality systems and reaped the benefits. OMNEX typically conducts an initial assessment which culminates in an improvement plan. Implementation can begin after the companys executive team evaluates and finetunes this plan. We then use business and quality systems methodologies and tools to implement the plan. Close to 15 % of waste reduction, reductions in customer complaints, internal and external rejections etc are not unusual in an Omnex quality improvement project. OMNEX not only improves the client's product quality but also facilitates cost savings in improvements to business processes, while meeting and exceeding customer expectations. This enables our clients to maintain and expand their existing business in the face of ever-increasing competition. We are interested in demonstrating to your top management how our capabilities in Quality management systems world wide can be combined with your resourceful business system, to successfully penetrate and sustain in the competitive global market.
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