Hi folks,

I need a template of a Quality Manual for TS-16949:2002.

Thanks

I'm about 80% complete with one. Actually, I modified an ISO 9000:2000 that I picked up here. Do a search on Quality manual for ISO9000:2000 and add the extra requirements. Or when I'm done, I'll forward to Marc for the files directory.

Laura

Laura M,
Congrats on your progress. I'm just getting started.

Just a couple of questions:
- a quick review of the standard finds that there are only 6 documented procedures required. Have you found that you can limit the number of procedures?
- How has your manual changed from the QS, i.e., relative to the new process mapping requirements?
- Have you attended an AIAG TS auditing course? What are your comments on the course?
-Are you using the AIAG checklist and guidelines?
- Have you selected a certification body? What is your cost to upgrade?

I can't answer them all, but here's the ones I can.

We did not combine any procedures. But be careful TS adds a requirement for a training procedure. CA and PA could be combined, but ths client implemented a very simple PA system.

This manual is new for the client. I following the new numbering system and referenced procedures, which is the basic philosophy I used for QS.

I have been audited to ISO - Y2k, so I'm following the same process mapping - with the added requirements where they fit. I don't think some fit well in our processes where they are in the standard, so the procedure references in the QM handle that.

Nope - haven't attended an AIAG course. I going on the fact that I've been in this game for awhile, passed ISO Y2K upgrades, and TS is just extra requirements. I do plan to attend. I guess its on the list for the fall sometime.

This particular client is not upgrading - they are going for it out of the chute - so I can't comment on upgrade costs. But your registrar should provide a quote. They are using NSF-ISR.

Laura,
Thanks for the feedback. Sounds like everything is going OK.

Laura,

I also following the same route what u are following. We were certified an ISO 9001:2000 Company on 15th December 2001. From that day onwards we have started the journey towards ISO/TS 16949:2002. We have already done process maping as per 9K2K requirements. Regarding HR procedure, Ya Employee motivation and empowerment procedure we have added, Supplier Developement procedure is extra and we have made it and started working to implement. One more requirement is towards MSA, Control Plan, FMEA, APQP and PPAP. I don't think further more requirements are there over and above 9K2K.

Manoj,

Can you pls. explain as to what exactly you mean by 'process maping'. An example would be very much appreciated.

Rakesh

pl. find attach the Employee Motivation and Empowerment Procedure. Pl. make it more smooth and suggest.

Manoj Mathur

HELP!!! I'm just been given the task of transfering our QS9000 manual over to TS. While I'm doing this I've to slim down the manual. I would love someone to give me advice on how to do it!!!

We are in the process of going from QS to 16949. I am also using a 2000 manual and adding the TS additional requirements. I would also like a copy of your manual when you have finished. I would just like to see the approach/format someone else has used. I would also be willing to share my manual when completed.

:biglaugh: :smokin:

sure you can have a copy when they're done.

We are aming to be certified:bonk: march next year

Thanks, we are shooting for June 03:bigwave:

. I am the QS9000 coordinator trying to implement the system here. However, we are now trying to decide if we should go ISO-9K2K, and TS16949 since the QS is being replaced, and our customer has asked about our TS16949 plans. I am really in a quandary due to the fact we are behind on our QS implementation schedule( due to management focus on new business start up), and would it be now feasible to switch, and would there be cost savings to do this. Since you have been through this, I was hoping you could offer some advice to a struggling coordinator. Also could use some manual templates if available.

Frankly I would go for TS as the Big 3 have officially announced that QS dies 12/14/06 and TS will take its place as an international standard. As for cost that you have to discuss with your registrar

Is ISO9K2K registration a prerequesite to implementation of TS16949, or is TS a stand alone standard, or are they concurrent?

You are not required to become ISO9K2K before becoming TS. TS is based on ISO9K2K, it is just ISO9K2K with the additional requirements for TS, the same as QS was based ISO9000:1994. However if you can not be certified to TS by 12/15/03 then you will have to obtain certification to IS09K2K first then upgrade to TS by 12/14/06

Thank you Billie, and Laura for responding
Appreciate your input
Ralph

An interesting little note:
Whereas Ford and GM still regard TS 16949 and QS9000 as having the same "value", Visteon now give 20 points on their supplier evaluation for 16949 certification and only 15 points for QS9000 certification.

That is an interesting note, since Visteon is our primary automotive customer. Thanks for the tip

I would agree that going for ISO/TS 16949 certification is the way to go. Messing with QS-9000 doesn't make sense because of it's limited life and the fact that it is not compliant with the new process model approach required by ISO/TS 16949:2002 and ISO 9001:2000. However, I do not understand the comment that if you could not be vertified to ISO/TS 16949 by December 2003 then you would need to certify to ISO 9001:2000 first and then upgrade to ISO/TS 16949. Unless you have a customer mandating that it would seem an unnecessary step.

The reason for the comment is that if you are currently registered to ISO 9000 1994 version then you must be upgraded to ISO 9000:2000 by Dec of 03. Therefore if you can't make TS by then you will have to go for ISO 2000 then upgrade to TS.

We are an ISO 9K2K company and planning to have TS 16949:2002 in the month of September 2002. We have prepared a Quality Manual for TS 16949:2002, Which I have modified from Quality manual from ISO 9K2K only. As I have indicated I have addressed some more requirements over and above ISO 9K2K. These requirements are such as
5.5.2.1 Customer representative
5.6.1.1 QMS Performance : I have mentioned how we are calculating COPQ
6.2.2.4 On job Training
6.2.2.4 Employee Motivation and Empowerment
6.4.2 Cleanliness of Premises.
APQP, FMEA, PPAP were also mentioned.
7.4.1.2 Supplier QMS development

some more and that is all.

If you want I shall be sending it to you.

Manoj Mathur

That would be great and if I can help you anyway in return let me know.

Manoj,
Yes, that sounds great, you have really accomplished a lot.
congradulations for you efforts

Billie,

I understand that ISO 9001:1994 becomes obsolete and that that QS-9000 or ISO/TS 16949:1999 loses its ISO 9001 certification status at that point. However, if your customers are only requiring you to be certified to the QS-9000 for example, then it really wouldn't matter if you let the ISO portion slip until you are ready for the upgrade or until the customer's deadline has expired. QS-9000 would simply become a stand alone certification during the interim.

Yes but if you are not already QS why would you want to spend the money to certify to QS when in 2006 you will have to be TS. That was my only point. Ralph stated his company was only IS0 1994.

I just stumbled onto this website today and immediately became a member. I am just beginning to convert our qs9000 quality manual to TS16949:2000. It would be great to get a copy of a TS quality manual! How do I access the files directory? Or where else can I get one from?

Thanks,
Denise

I'm not trying to start an arguement and I'm not trying to point fingers here. But I see all these requests for a copy of QM's. I will gladly share the structure I'm putting together when I'm finished but don't you think designing your own will fit your company better? A cookie cutter mentality is what has caused such problems with QS and ISO in the past. As long as you address the requirements then an auditor doesn't have a means of finding fault. I did the same thing starting in QS, I let a procedure software design my system and it took me 2 years after getting rid of the software to fix the system. It's not an easy task but put some thought into it. Not only do you come away with a better understanding of interactions in your system and processes but you have developed a unique system that is a glove fit for your company.

It just scares me when I see a bunch of fill in the blank operating systems. As an auditor it causes me to put it "under the microscope". I have found in systems that are based on software or copies, no one other than the QS/ISO coordinator and maybe the QM will have a clue of how the system works.

I'm not judging just offering an opinion.:truce:

Randy,
Thanks for your input. But why make something from scratch when you have a 'template' to start with. It's a more efficient way to do the job.
I did not write my company's first Q manual and frankly, I feel that they went way overboard. I want to be able to compare our manual to a manual that was written by a knowledgeable, objective person. I will certainly put many more hours into shaping it to serve the needs of my company.
So, any help that I can get would be of great assistance to me and perhaps to others, too.

Sincerely,
Denise

I agree with Denise, seeing a "template" of form and content is useful to evuate how others put together structure addressing the requirements. Everyone has their own needs and methods, and it is foolish to just copy another system, and put your name on it. But, why re-invent the wheel. Some of us have not been through these systems entirely, and are looking for direction from knowledgeable people who have. We are going through these together, so why not help each other to reduce the agony.

I know, I know. That is why I stated that I will gladly share my format when I'm done. Work Smarter, Not Harder. I agree with the template I just don't want to see people make the same mistake I did when I started on QS.

I'm more than willing to help and I will post what I have developed. I have received a lot of help from others sharing Flow Charts and Procedures. So please don't get the impression that I'm against it. That's not what I was trying to point out. Maybe it was caused by the internal audit I just completed that I sounded so negative. Sorry if I offended anyone.

Hey Stew, no offence taken here. Internal audits have tendecy to alter ones attitude, whether on the giving or receiving end.
TGIF

When I work with a company, I often give them a template to assist them in figuring out the QMS. The templates are deliberately written so they would have a hard time with just ‘insert company name here’. What the templates do, is to provide the user with a basic understanding of how QMS’ are written and implemented.
On occasion, I do have someone ask if they have to have a “Senior Vice-President of Supplier Development”, as outlined in my template. My head might stop hurting if I quit banging it against a wall!
:frust:

Hi everybody:bigwave:
This is my 1st time joining this forum that I think is very usefull for changing information & experiences. I'm responsible to convert our QS to TS and now in progress of developing our QM. Our company is producing Home Audio Entertainment and Car Audio Systems. Some of our car audio products are OEM to automotive industry. The problem is only partial of our products need to comply to TS while others remain to ISO9001:2000. Can somebody advise me how can I identify these requirement in my quality manual?:confused:
Hope can hear from you all..
Thanks.

You can use a different font and state that 'requirements in italics' are for OEM auto customers only. Check with your registrar tho. This worked for me in a QS environment anyway. Haven't tested it yet under the TS rules. Some TS requirements you can't separate out - like business plan, quality plan, etc where it may not make sense to have 2 systems depending on the customer.

Also you may need to address the differences in the registration scope.

Agree!.

I've done the same thing for the current QS: two different scopes, one for Qs, one for ISO.

In 4.3 Contract Review, I classify each job to either one of the scope.

I am doing the same for the TS, and it is OK with my registrar.

Paul N.

A chart by Radley Smith of the Management Resources International Inc. which gives a detailed map to bring your quality manual up to date, can be found at www.mri-inc.com or phone 1-734-429-0747. There is also a Transition Planning Guidance for ISO 9001:2000 at www.iso9000.com - the document is ISO/TC 176/SC 2/N474R March 2001. Hope this helps.:)

Thank you very much for your comments and information:)

Me too?

:frust: I too need a TS 16949 template manual and feel there is nothing wrong with wanting a template to get you started. That's why we get audited every 6 months, to insure that we are following our manuals. If all I wanted was a TS manual to shove under a auditor nose, then that auditor is going to know what up by the end of the audit and the company I work for would have wasted alot of money trying to move ahead.

QM Template: (ref 4.2.2)

the quality manual shall include;
- the scope of the quality management system, including details of and justification for any exclusions(1.2).
* the scope as it will appear on your certificate.
- the documented procedures established for the quality management system, or reference to them,
* there are only seven documented procedures required. list these by number. you may add additional procedures if necessary.
- a description of the interaction between the processes of the quality management system.
* process mapping; depending on the type of process, will include a process flow chart/control plan describing the inputs and outputs.
This information makes up the requirement for a quality manual.

Suggestion:
1- read notes 1,2 & 3 at the end of 4.2.1.
2- in the spec highlight the term "documented procedure(s). should be 7. if you are QS you should already have these procedures.
3- highlight the term "process/processes" and the "shall" that goes with it. Do you have a document that fully describes the process? if so, use it. If not prepare a process map.
4- Highlight the remaining "shalls". Yuo should have existing document that satisfies these requirements. If not, consider using a process map.

Everyone:

I always try to do it ,but always haven't clear proposition,could you tell me particular ;

I think program maybe include scope , nomenclature,responsibility,input,output,work program,inspect,record;
may I?
I think flow chart instead of input,output,work program,inspect may I?

jan2

Jim

TS16949 also mandates procedures for the identification of training needs and achieving competence.

Why ?

Because trainign is probably the single most important thing in the QMS ? Maybe ??

Training is part of the system is it not ?

Why does it appear in the QMS standards if it is not part of the system ??

A system failure could well be lack of training, or poor training.

So you can knock your bleeding laughing faces on the head wise guy :mad:

Hello Everybody!

Please find attached our Quality Manual.
It is in two Zip files.
Pl. give your feedback on it.

Hello Everybody!

Please find attached our Quality Manual.
It is in two Zip files.
Pl. give your feedback on it.


OOPS!


Actually I found that Even the Zip files are 4 MB sizes and I can't send it thro this route since max limit is 80000. Hence I am sending one part of my quality manual wishing it reaches to you. Can you suggest me how can I send it the complete manual.

Jim,
The same six plus one for training. Para 6.2.2.2

Manoj,
Looks good. I do have a question. Are those actual procedures or are they process flow charts?

I am interested in how you handle the procedures for your manual. I would appreciate a copy of the procedures. If you cannot send the complete procedures over the e-mail, my particular interest is the continual improvement CQ-8. I am presently revising the continuous improvement section of my Quality manual.

I know this topic is a hot one when it comes to companies wanting to go from QS to TS or something similar. I would love for someone to e-mail me a "template" of a TS manual converted from QS. However, I would really like advise from those that might have an educated opinion on the idea of going for TS by the end of '03 (from QS) or going QS and ISO92k(seperate certifications) then TS later. (of course this means $$$$$).

I would like to "convert" my manual from QS to TS and get registered by '03 but is that really possible - especially not being familar with ISO92k and the differences from ISO9000:1994 (i.e. process approach)?

I work for a commercial heat treater which does a large amount of automobile components, where should I focus my energy?

Tom W
DC rwquires TS for 2004. If yiou do Business with DC then I would suggest starting now for TS, otherwise you have until 2006. I would skip the 9K2K/QS and go directly for TS.
Your CB will let you know if your ready. There is a tremendous amount of data that is required to be presented to your CB for review prior to there visit.
Example:
- quality manual
- Internal audit and management review planning and results from previous twelve months,
- list of qualified internal auditors,
list of customer specific requirements,
- customer complaint status,
- operational performance trends for the previous twelve months, minimum.

Plus additional data as required by the CB which may include:
- Customer oriented processes (COP's)
- support processes for the COP's,
- list of OEM customers'
- copies of third party audit results, if you are using a different CB then used for QS.

After reviewing the data the a decision will be made to determine the need for a pre-audit.

If a company you complies with every "shall" in QS then I would estimate that company would be about 80% compliant with TS.
Mangement review is more specific, auditing adds process and product audits, trainig has a new twist.
Mfg. planning is big change, same as product design. Product realization is new word for an old topic; APQP.
Chaotic area; IMO process audits. I have heard that auditors are still looking for procedures as opposed to process mapping. Process auditing and procedures do not go well together.
We are "scheduled" for our registration in May 2003, so time will tell.

So how does one start this whole process from switching from QS to TS? I am starting from nothing except a QS9000 quality manual from a sister company that will be supplying us raw. We have no machinery or people hired yet. I have started on the quality manual on the sections that I can address at this point. I am just confused on the element/section thing. When I write up the manual, do I go by the Standard and write it in that order? or do I go by processes and have the manual all mixed up?

Hi folks, this is my first posting on this system. Kind of a slow night for me, so I did a Google seach on TS2 and ended up here.

I'm one of the Registrar Auditor Master Trainers for TS2, as well as QS-9000. In other words, I'm one of the folks that certify the CB auditors. I do most of my work out of AIAG in Detroit, and literally work across the hall from the IAOB office.

Seeking a "template" QM for TS2 is an exceptionally bad idea, and not really necessary. An elemental-style manual, restating the requirements of TS2 and describing how the organization intends to comply with the requirements is not necessary (it wasn't necessary for QS-9000 either, but I'm not going down THAT road again), and may in fact be a warning to the CB auditors that an organization has not taken the proper approach to TS2 implementation. We teach them to look for that.

Per clause 4.2.2, the QM needs to contain the scope of the QMS, including details and justification for any exclusions, the documented procedures established for the QMS (or reference to them), and a description of the INTERACTION between the processes of the QMS - THAT'S IT. I know of a registered organization that has a 1 page quality manual - it can literally be that simple.

By far the most important component of the quality manual is the piece on interaction of processes. That will form the basis and structure for both the QMS and the certification assessment. This can take any form - process maps, flowcharts, Venn diagrams, text descriptions, and so on. The key point is, has the organization defined itself as a system of processes, and determined the sequence and interaction of those processes, in order to effectively fulfill all customer requirements.

CB auditors will use this information as a key input to their audit planning. Folks, the audits you are about to face for TS2 will be radically different from QS audits. No more walking in with the QSA and running down checklist items. The CB auditors will focus more than ever on conformance to CUSTOMER requirements - and if they detect non conformance to ANY customer requirements, you can expect major nonconformances. That is the dictate we Registrar Auditor Master Trainers were told by the IAOB to pass on to the CB auditors.

I've got lots more information on TS2, and I'm in a pretty good position to do rumor control. I'll post some more later. Nice meeting you!

Don Wood

tell me more Don........

It's music to my ears, Don. We have had a few debates on this topic over the years here at the cove.
Not only is much of the stuff not required by the 'standard', it often has absolutely no business purpose either.
I agree Jim. Too often in the compliance/conformance arena we tend to follow the well beaten path of what worked for others, than to try to blaze the new trail of what is needed for us. So much with the auto business rides on getting that certificate that we do the "dog and pony" show for the auditors and say forget good business sense.:bonk:
:thedeal:

Wow Don

Please stick around and give us all your sound advice.

Hope you can teach some of those very experienced people that are still stuck in their bad old ways :thedeal: :rolleyes: :vfunny:

:confused:
This is my first post so please bear with me.
All of this quality stuff is new (zero experience) to me, as I have recently been deemed management rep for a one year old company.

The quality manual I have written is no more than five pages. It follows the requirements of 4.2.2 with just a few extras. I referenced the seven required procedures and placed in a simplified process map (with references) for process interactions.

I am developing more indepth process maps to completely define interactions as well as to act as work instructions, as pictures are worth a thousand words. From the standard this should suffice as far as the QM is concerned.

My personal feelings are that the quality manual should be used as a staging point for the QMS, not a book that only comes out for audits.

I would appreciate any input anyone can give me. Hopefully I am not completely of base. If so, someone please tell me before I embarress myself.:ko:

Todd,

From what I read in the last little bit, that seems the approach to go. I am going to attempt the simplified method too. I guess we will both know after a pre-assessment.

Sam,
I closed out all my programs and tried to open that .doc and it comes up with the spreadsheet. It looks like Martin (?) was able to open it though as he offered you feedback on it.

Thanks for your patience,

Allie

Todd,
IMO, you are taking the right approach. I'm doing the same. As I develop the processes I can always go back to the manual and make a change if I need to.

Thank You Don!!!!!!!!!!!!!!!!!!

I dont believe anyone really wants to copy a manual - the problem is there is no guidance and people do what they think is right and have only to wait until an auditor comes in to find out if it is right - then it is too late so they type up procedures and instructions (myself included) to cover word for word what the standard states becuase depending on the auditor coming in; they decide for you what is right and worng.

I am on a time constraint to be certifed to TS by next November 2003; so I'm looking for any help I can get on the process maps. All I was told by our auditor is that there is no worng way to do it. Yeah ok................

Is it advisable for the same person to be both the Management Rep and the Customer Rep?

(sorry if this is a dumb question)



Allie

Martin and Jim,

I hear where you're coming from. I had to learn a whole new way of thinking myself when I got involved in this line of work. I'm lucky to have the opportunity to work with some of the best folks in the country - and perhaps the world - on TS2. Talk about a blind squirrel finding a nut!

I would urge the consulting community to attend AIAG training on TS2 before making the assumption that TS2 is going to be handled just like QS-9000 was. The emphasis on TS2 is squarely on processes and conformance to ALL customer requirements - part quality, delivery performance, process performance, and so on. The "paperwork mill" approach to QS that many (perhaps most) companies used (including, I'm now embarassed to admit, my first implementation) will not fly in the TS world.

"Elemental" audits are going away as well. Process Approach auditing as mandated by the IAOB will focus sqaurely on the ability of an organization's processes to meet customer requirements - ALL customer requirements. CB auditors will be expected to understand and analyze an organization's processes, and structure their aduits accordingly, developing specific, focused questions based primarily on process performance and determining if customer requirements are being met. The auditors will dig a lot deeper then ever before, especially when a process isn't performing to customer requirements. It's going to feel a lot like a second party audit in that respect. The Quality Systems Checklist is intended to be used as a planning aid (to ensure that all TS requirements are covered in the audit plan), and at the conclusion of audits to ensure and document that all TS2 requirements were examined.

Guys, the IAOB (and the automakers they represent) are dead serious about this. Check out the IAOB website and read the communiques. Attend one of the AIAG rollout sessions. I haven't confimed this independently, but one of my contacts that works with AIAG said that last year, the automakers recalled more cars than they produced! And the lion's share of that is due to supplier quality issues. I've worked most of my career, and I know that the automakers themelves are not exactly blameless in this, considering some of their procurement and cost-reduction policies, But let's face it - in this business, it's the Golden Rule. They have the gold, they make the rules. And they're sick of losing market share to the Japanese because most people perceive Japanese cars as being better quality and more reliable.

I have personally heard the DC rep to the IAOB state, on more than one occaison, that if the automakers do not see significant improvement in supplier quality, THEY WILL GO BACK TO SECOND PARTY ASSESSMENTS! The GM rep has publicly stated the same thing. I don't think anyone wants that, and before you pooh-pooh the notion and think to yourself "Nah, that'll never happen."
let me tell you. I looked the DC guy in the eye whil he was saying it, and I believed him. **** skippy I believed him.

Under the new scheme, if the IAOB gets reports from the automakers about quality issues with suppliers, THEY may choose to initiate the decertification process themselves. You can see that outlined in the "Rules for Achieving IATF Recognition", availble from AIAG. For TS2, CBs have contracts direct with the IAOB, and the IAOB has responsibility for conducting witness audits for TS2 - NOT the IAOB. If a number of suppliers with quality problems are clients of the same CB, then the CB's contract with the IAOB could well be in jeopardy. There's only about 50 CBs worldwide sanctioned to perform TS2 audits - that alone should tell you something (the list is on the IAOB's website).

The winds of change are blowing, and knowledge is power. Before you assume that TS2 is going to be like QS, get the straight scoop from the folks that are close to the process - AIAG and Plexus. You won't regret it, except as you may regret getting involved in automotive in the first place! ;)
DW

I meant to say the IAOB has the responsibility to perform witness audits, NOT the RAB, for TS2. Sorry, it's been a long day!
DW

Hi. Yet another first timer

I stumbled across the Elsmar Cove Forums whilst searching through Yahoo for assistance in preparing my Company for transition to TS 16949, and it appears to be a wonderful forum for like minded Quality Professionals to share their knowledge and experience.

I am spending a lot of time converting my ISO 9002 system (skipping QS 9000) and was hoping that someone could help me with production of my Quality Manual. All I am looking for, is ideas for simplifying my manual and avoiding time consuming mistakes.

If I can do anything to save some time, by drawing on the good work already completed by others, I would be really grateful.

Hoping someone can help, I look forward to hearing from you soon.

Thanks, Mick

First of all Mick, Welcome to the Cove!!!:bigwave:


I think it is important that you not throw away all of your 9002 stuff. It might be useful later.

Now, why 16949? Why not just 9001:2000? The intent of the task force is that not all QS companies will qualify for TS. You might want to check to see if it applies.

If you do, then get a copy of the standard and the checklist. Perform a gap analysis to determine what areas you need to do additional work.

Two key things:

1) There is great emphasis on process thinking. Audits will have to be based on the process, not just the standard.

2) There is a greater emphasis on customer satisfaction than in 9002. Look at those parts of the requirements.


One last thing. If you have any specific questions, perform a search of the Cove, based on your needs. There is a wealth of knowledge here.

Once again: Welcome :bigwave:

Thanks Dave

Unfortunately, I do have to seek registration to TS 16949. We are currently Ford Q1 approved, and they have been pushing for QS 9000 approval, but we have decided to go the other route, because of our current and potential European customers.

I suppose that what I am looking for, is a copy of someone's Manual, to get a feel for the set up. Processes are not a problem, and are mostly complete, diagramatic and flowcharts etc, but I don't want to waste my time on a complex manual if I can borrow someone else's ideas for a simple version.

Thanks again. Mick

Mick

The TS requirements are:-

4.2.2 Quality manual
The organization shall establish and maintain a quality manual that includes
a) the scope of the quality management system, including details of and justification for any exclusions (see 1.2),
b) the documented procedures established for the quality management system, or reference to them, and
c) a description of the interaction between the processes of the quality management system

The big difference from your 9002:1994 manual will be items a) and more importantly c) above. Also you may note that you no longer have to regurgitate the content of the standard in your manual - hooray.

Some people have spoken of one page manuals, I havent seen one yet, but it will probably be a slimmer document than your current manual (assuming you have followed the time honoured tradition of copying ISO9002 into your manual).

I have heard that the manual should be smaller, mainly because of 4.2.2 being specific about what is required. The only confusion seems to be in the interpretation of (c).
What would satisfy "a description of the interactions between the processes of the quality management system"?

I am trying to avoid a regurgitation of the standard.

:bonk:

What would satisfy "a description of the interactions between the processes of the quality management system"?

Examples of your process diagrams would be easy

Regards

First post, so don't know if this will get through. I've been brousing here for a month now. All of you have been VERY helpful!! Thanks!!!

Hello dbzmzn!
I agree with Mr Morrow, but be sure to include ALL your processes, not just the manufacturing flowcharts. (Employee Motivation, how you determine customer satisfaction, and the other requirements of the standard).

By the way, I'm trying to figure out the best way to do this myself. I've tried a cross-functional flowchart, a responsibility matrix, and written descriptions (similar to a written procedure) to describe our processes (for a design responsible company employing 150 people). They all have their good and bad points, as far as explaning the processes. What have all of you found to be the best?

Interaction - could be a matrix showing which processes link to each other.

Hi Mick,

I also am a new user of the Cove but have been visiting for a while, can I suggest you talk to SMMT and have one of their reps in. We have done this on our site and they were extremely helpful and have helped to drive our certification process, and their prices are good too.

PS I no don't work for them nor have done, I have simply had the pleasure of working with them

Dave

please please someone help me i am lost with this manual business especially with the process bits that have to be added mine is not making sense someone send me draft version as template so that i can see if i am way off the mark or not too far from the way to do it.

Hello,

When I did manuals for ISO9000 and QS9000, I went through each element, describing how we met it and where the procedures/evidence etc could be found.
This was a pain in the arse but did give some confidence that all clauses were addressed and showed up where we were a bit flaky.
Now with TS16949 we don't have to go clause by clause, we can have a little skinny manual - yippee.
However, we're encouraged to download and fill in the "Process identification tool"
This involves much skipping about different excel worksheets but to my eyes then gets the victim to look at each clause and sub-clause of the standard and fill in how it is met, what procedures apply and where is the evidence.
Sounds familiar.......
Maybe I interpretted it wrong, but I gave up and went back to listing each clause in the manual - it was much easier.
Has anyone come to a similar conclusion?

Brian

.......................................................................
"I said "'I'm so happy I could die"
she said "drop dead" and left with another guy" E.Costello

Brian Dowsett

I agree. I also have two other standards that are included in our manual and found it much easier to list the clause in the manual.

While I was developing the manual, procedures, forms, flow charts etc, I maintained a database that tracked exactly where in the manual I could find the reference and the same for the procedures. I did not tract forms and such because the procedures are hyperlinked to them. This tracking process allowed my to complete some of my documentation in record time. I did not have to flip anywhere, I simply did a print out. This method was a bit more work at first, but continues to make my life easier. I also used this database to develop audit criteria and agendas, track forms, revisions, corrective actions, continuous improvements etc. I don't have a lot of knowledge of databases, but was able to develop and usefull and simple one.

Is ISO9K2K registration a prerequesite to implementation of TS16949, or is TS a stand alone standard, or are they concurrent?

ISO9000:2000 is not a prerequesite to TS16949. My company was ISO9001:1994 so we opted to upgrade to ISO9000:2000 then work on our TS16949 certification. The reasoning behind this is that if you are ISO9001:1994 you have to be upgraded to 2000 before December. Also, I have done all the work in my upgrade to format to the 2000 standard which is what the TS16949 is in. Now I have to add all the supplemental things from TS16949 in and then check the customer specific requirements to make sure those are met. Any tips would be great!!!!

Hello,

When I did manuals for ISO9000 and QS9000, I went through each element, describing how we met it and where the procedures/evidence etc could be found.
This was a pain in the arse but did give some confidence that all clauses were addressed and showed up where we were a bit flaky.
Now with TS16949 we don't have to go clause by clause, we can have a little skinny manual - yippee.
However, we're encouraged to download and fill in the "Process identification tool"
This involves much skipping about different excel worksheets but to my eyes then gets the victim to look at each clause and sub-clause of the standard and fill in how it is met, what procedures apply and where is the evidence.
Sounds familiar.......
Maybe I interpretted it wrong, but I gave up and went back to listing each clause in the manual - it was much easier.
Has anyone come to a similar conclusion?

Brian

.......................................................................
"I said "'I'm so happy I could die"
she said "drop dead" and left with another guy" E.Costello
I created my manual in word then linked my flowcharts, forms, process assessment worksheets and sops. This works great for me but my registrar told me that these are part of my quality manual now and when I update them I will have to send them a revised copy of the whole manual. I found that a database is great for tracking.

If I understand what you said, I disagree with your registrar. Tell your registrar that forms, flowcharts, SOPs, etc. are not a part of the manual, but are referenced in the manual. To me a link is no different than a reference to an outside document. It's absolutely ludicrous for them to expect you to send your entire document system to them any time you change one document!

Discuss this with your registrar if it presents a problem. They do need a copy of the changed document so that they can review the changes prior to auditing your facility.

We are in the situation where a consultant compiled a Quality Manual for us and it is a huge document!!! We are aiming to simplify the whole system and make it more user friendly and value adding. One area that needs urgent attention is our Quality Manual because it is not being looked at by anyone, due to the fact that it is basically a replica of the ISO/TS standard. I would appreciate it if you could e-mail me examples of your Quality Manuals, where possible, so I can have a good idea where to start with simplifying the manual but still meeting the requirements of TS.

Excellent job on your manual.

Hi Don Wood and the rest of you fellas,

This is my first time posting in this forum. I have been searching for a gap analysis between ISO 9001:2000 and TS 16949. However, I have not been successful.

Thanks guys and gals,

Best Regards
Thunderlord

Hi Don Wood and the rest of you fellas,

This is my first time posting in this forum. I have been searching for a gap analysis between ISO 9001:2000 and TS 16949. However, I have not been successful.

Should there be anyone with this gap analysis, please email me at samuelng1@hotmail.com.

Thanks guys and gals,

Best Regards
Thunderlord
I posted a checklist here (http://elsmar.com/Forums/showthread.php?t=6475) that may be useful to you. If you need it emailed, let me know...

Hi Michelle -

That's the checklist I emailed to you last Thursday... :D

Hi Michelle -

That's the checklist I emailed to you last Thursday... :D

Whoops!!!! I am sorry. At the moment I don't know if I coming or going. I am just looking for as much help as possible....

Hello Helpful Ones:
I've been lurking here for years and finally managed to get the software to register me. I hope to give as good as I have received. I was project mgr. and QA mgr. for a successful ISO9001-1994 registration at a 2 site, 250 employee, $50m/year co. in 1998 (we converted from a 10CFR50, Appendix B [nuke] system in 9 months). Much help was received here. I am working on convincing "Top Management" at my current employer that a TS2 registration is worth it. Anyway, I don't have any TS16949 experience other than common sense, so take the following with salt:
Word 97 TS16949 "parrot-back" manual (TS2 requirements in blue text)
Word 97 ISO9k2k "short-as-i-can-make-it" manual (this requires one of the interaction descriptions)
Excel 97 "inputs and outputs by section" that IMO covers the interaction of processes verbage
PDF "process map" of the inputs and outputs by section (note that our customer communication section includes internal customer satisfaction ratings and workplace organization ratings so your results may vary).

I was inspired by damonhill's ideal of a 5 page manual. I carefully considered where the information required by each TS2 section would come from and where the output would go. Also, I pared 4.2.2 down to the bare minimum required in the QAM.

Comments encouraged and appreciated,
I hope Marc doesn't kill me for the massive upload,
John Humphries
Vanner, Inc.

I'm neck/eyeball deep in same process of paring down a HUGE QS manual and program to something more sensible for TS. We are finding some procedures are flat out being eliminated (ie, Business Plan) and we're doing a LOT of combining, so I guess we'll end up with something like half the number of procedures.

Hi! Everybody

I´ve been developing process interaction diagram and have come to this
please I´d like some feedback about it, any comment positive or negative.

Thanks in advance

:bigwave:

It's not that dis-similar to the one we're working on here, but we started out with listing all the applicable docs and standards sections and such as you have here and then abandoned that in favor of KISS (keep it simple) and use another excel document to make all those types of connections.

tattva, if you created that in powerpoint you must have the patience of a saint! (Get a copy of Visio, well worth the expense).

I will be honest & say I find it a bit hard on the eye. If I had inherited that, I would stick a number in each process box, and have a matrix as an appendix crossreferencing your red procedure numbers? to the box number. Maybe strip the clause references out into the matrix as well.

The square boundary boxes I would change to solid coloured lines.

I would then annotate the arrow lines between the boxes & say WHAT was transferring (the Input/Output).

Icy Mountain,

Your Objectives in the short QM seem a bit vauge - dont they have to be measurable? Your QP says "We define quality in electronics as
robust design, reliability, and safety of product operation". Shouldnt one of your Quality Goals be "Ensure average reliability of 10,0000 hours MBTF" or something like that.

Check out this thread on Objectives;

http://Elsmar.com/Forums/showthread.php?t=6430

Especially the attachment posted by howste.

Now the map, is that really a map of the processess of YOUR company, or all the clauses of TS rearranged?

No offense given to anyone - only my opinion (right or wrong) that was asked for :)

Non taken! I asked for this

But perhaps You can let us take a look at yours and then redisgn ours. Don´tu think? :thedeal:

Your Objectives in the short QM seem a bit vauge - dont they have to be measurable? Your QP says "We define quality in electronics as
robust design, reliability, and safety of product operation". Shouldnt one of your Quality Goals be "Ensure average reliability of 10,0000 hours MBTF" or something like that.

Now the map, is that really a map of the processess of YOUR company, or all the clauses of TS rearranged?

Shaun,
Hey, I asked for it!
Yeah, the Objectives are vague and lame. 5.4.1: "Top management shall ensure that quality objectives..." and they are not on board yet. :frust: Yours will be the first example I use when I lead them through the establishment of "...measurable and consistent with the quality policy."
I should have explained the map better. I ignored the TS subclauses in the SHORT manual and map, since I plan to cover all but the most specific clauses in my ISO QAPs (e.g. QAP 7.5.5 will cover 7.5.5.1 as well, but I will probably have a specific QAP for 7.5.1.5 since we do have an interesting tooling mgmt system). :o We use a Team Based Organization model where internal "teams" are suppliers/customers in the product realization chain. They rate each other for customer satisfaction and "workplace organization" (6.4). Therefore, sections 5.2, 5.5.3, 6.4, 7.2.3 and 8.2.1 may be tangled up in ways that would not fit an organization with an internal communication system that is not process integrated. It is an example. Like everything in these forums you must understand the standard and adapt it to your system. I sent the editable Visio 2000 file to Marc so he could put it in the premiums.
-John

There are copies of my overall & lower level flows on this thread - comments welcome! I have tweaked the overall flow recently, but I dont have a new copy here at home.

http://Elsmar.com/Forums/showthread.php?t=6570

Hi! Everybody

I´ve been developing process interaction diagram and have come to this
please I´d like some feedback about it, any comment positive or negative.

Thanks in advance

:bigwave:

Good job !

Desde mi punto de vista se ve completo..

Los PTC, PTP, etc, son lo sprocedimientos/ intrucciones que cubren cada proceso ?


Que tipo de programa utilizaste ?

Believe it or not! I used powerpoint, someone said i had the patience of a saint to do this in powerpoint. I don´t think I´ve that patience.

De cualquier manera gracias

:bigwave:

I have the quality manaual and procedures for Ts 16949. However last week we started our internal audits and a supervisor and an employee in charge of purchasing stated to the auditor they didnt read the procedures. TS 16949 training using the requirements of the standard was given to all employees. The manual and procedures were available to them over 6 weeks. This is a small company with very little time to get together. Any ideas how to facilitate the process and ensure or at least establish objective evidence that these documents are being read and used.
When a work instruction changes we state that the supervisor is responsible for reviewing the chnage with all personnel. I would like more involvement and to see training documented with each change but time and people restraints are not going to allow this.
I would appreciate ideas.
For those still looking, i do have a manual to share

IDAY38,
List the required documents on your training records and require that the employee, including the supervisor, sign the record indicating they have read and have been trained in the contents of the document.

IDAY38,
List the required documents on your training records and require that the employee, including the supervisor, sign the record indicating they have read and have been trained in the contents of the document.

That's what we are trying to do... doint it you have "training evidence" and nobody can't say that "nobody told me that" or "nobody train me" or "I dont remember", etc
;)

just had our assessment and have been recommended for certifiaction on closure of the few minor NC's found at audit. i am well chuffed not bad for 4.5 months work solidly to get this job done. my manual was even praised in my report as extremely good and this cheered me up and will cheer up all those people i have sent it too. they said it was the shortest but concise well written manual they had seen 17 pages not bad when 3 of those are contents page, front & back cover. as you can see i am well chuffed as i can relax now that the nightmare of TS is over i have 3 NC's to close off and then i can ask for a pay rise.!!!!


catch you all later
daman

just had our assessment and have been recommended for certifiaction on closure of the few minor NC's found at audit. i am well chuffed not bad for 4.5 months work solidly to get this job done. my manual was even praised in my report as extremely good and this cheered me up and will cheer up all those people i have sent it too. they said it was the shortest but concise well written manual they had seen 17 pages not bad when 3 of those are contents page, front & back cover. as you can see i am well chuffed as i can relax now that the nightmare of TS is over i have 3 NC's to close off and then i can ask for a pay rise.!!!!


catch you all later
daman

CONGRATS, ENJOY THIS SUCCESS FOR THR TIME IT LONGS;ALSO, YOU DESERVE A SALARY RISE.,

just had our assessment and have been recommended for certifiaction on closure of the few minor NC's found at audit. i am well chuffed not bad for 4.5 months work solidly to get this job done. my manual was even praised in my report as extremely good and this cheered me up and will cheer up all those people i have sent it too. they said it was the shortest but concise well written manual they had seen 17 pages not bad when 3 of those are contents page, front & back cover. as you can see i am well chuffed as i can relax now that the nightmare of TS is over i have 3 NC's to close off and then i can ask for a pay rise.!!!!


catch you all later
daman

Congrats and I think you deserve a raise also.

just had our assessment and have been recommended for certifiaction on closure of the few minor NC's found at audit. i am well chuffed not bad for 4.5 months work solidly to get this job done. my manual was even praised in my report as extremely good and this cheered me up and will cheer up all those people i have sent it too. they said it was the shortest but concise well written manual they had seen 17 pages not bad when 3 of those are contents page, front & back cover. as you can see i am well chuffed as i can relax now that the nightmare of TS is over i have 3 NC's to close off and then i can ask for a pay rise.!!!!

Congratulations!!!!

Yes, you do deserve a rise.

cindy

Daman,
Good work, and congrats to you, you deserve the best :agree:

EXCELLENT!

Congratulations on achieving the goal!

Can you share your experience? How tough was it compared with QS ones?

tattva,
I just paid for attachment access and downloaded your interaction map. It's fantastic! :eek: I can't believe you did that in Powerpoint! Are the PT... numbers listed in red your level 2 procedures? Are you willing to zip the other 4 sections listed and post it here?

thanks for all your thanks, this was much tougher than qs9000 because you had to prove that you did things rather than qs which gave you a list of things you must do and how to do them. it is whetehr your own method actually satisifes the assessor/the standard. i am now taking time off working half days only for awhile and i hope all of you do as well in your assessments if you need anything let me know

Manoj,

Can you pls. explain as to what exactly you mean by 'process maping'. An example would be very much appreciated.

Rakesh


Rakesh -- ISO 9000:2000 and therefore TS16949 require that you develop your
system on the basis of process flows. Many people had already done this
approach for earlier ISO 9000:1994 or QS9000, but it was not mandatory.

Usually we think of process flow diagrams for very specific processes, like
manufacturing 1 part. The new standard requires that you look at
your whole business in terms of process flow at a much broader level.
For example, what is your entire process for new product development--
from idea to completed product? Or your process for building product, from
order to delivery?


I recommend a few possible resources to learn more:

(1) TS16949 Implementation Guide - Published by AIAG
(2) TS16949 PRocess Mapping Tool - Also by AIAG

These docs are free if you are an AIAG member, or you can purchase them
if not. See AIAG.COM, look in the Quality section.

The general notion of process flow approach is also covered in the ISO
document Q9004:2000. This will cost a few bucks, too, but is often
included if you take an accredited ISO 9000:2000 course.


Regards,

Brad

anyone that wanted copy of my manual please e-mail me again as my work & home pc are playing up and messages have not got through to me.

sorry for anyone waiting too long

cheers
daman

Per clause 4.2.2, the QM needs to contain the scope of the QMS, including details and justification for any exclusions, the documented procedures established for the QMS (or reference to them), and a description of the INTERACTION between the processes of the QMS - THAT'S IT. I know of a registered organization that has a 1 page quality manual - it can literally be that simple.


Wow, I sure would like to see that.

Hello all, I am new to this crazy "quality" world. We need to transition from QS to TS. I am lurking about seeking examples so as to not reinvent the wheel. I am so glad to have found this forum (actually found by a coworker) and read all of your experiences. It is giving me a better understanding of all I have been reading and being told. I still have a long way to go.

Thanks!

Mary

Hello Mary and Welcome!!

I'm in your boat, having had to revise our manual from QS to TS.

The most important thing is not to freak out!

Many of the requirements are the same as QS.

The biggest change IMHO, is the process approach.
Attached is a file I found very useful (that I found here on the Cove)

Keep brousing around, there are some VERY bright people here. Let us know about your problems and possible solutions. (I, for one, could use the help)
daj

one more try to attach the file

Can't get it to work, sorry!!!

Mary, try a search for process mapping. It's a powerpoint file

Thank you Dave.

Is the ppt you are suggesting b_processes.ppt? Titled "Business systesm interactions"? I found that one and briefly looked through it. Otherwise, I shall continue to hunt!

Much gratitude!

Mary

Try this post by tattva:
http://elsmar.com/Forums/showpost.php?p=56201&postcount=105
the file is Process Interaction.ppt

Hi tattva,

I just found this site today, was curious to see your diagram, so I paid the "donation". Let me just say that it was well worth it! Very impressive flow charting! I'm looking for some sort of direction in changing our QS over to TS and reading over the threads in the Cove has been very insightful. Also, your chart will probably serve as a template for my ideas for our system. Thanks!!

Thanks you Icy Mountain! And Tattva!

It occurs to me that I could do my manual in one page. What do you all think about this?

A written scope that says we will comply with all elements of TS (something a little more elaborate).

A process interaction chart like the one Tattva posted, which includes references to the required procedures.

We could hang it on the wall. Who says it has to be in a book?

Wouldn't that be enough? It seems to me that would satisfy 4.2.2. Someone please shoot holes in my theory before I take this to my team and humiliate myself!

I am totally against writing a manual that reiterates the standard. That is what our current QS quality manual does, and it is an utter waste of paper and time.

THANKS!!!!

Mary

It appears to me that you have addressed the three items required by 4.2.2.
I see no reason why it should not work.
Go for it!

Wouldn't that be enough? It seems to me that would satisfy 4.2.2. Someone please shoot holes in my theory before I take this to my team and humiliate myself!
That's plenty! You will not be humilated, you will be hailed in the hallowed halls as a quality genius. :)
Seriously, you've met the standard, you're ready to roll. But with only one page where are you going to put your 4 color company logo, two page quality policy and all that other fancy stuff that the Marketing department wants?
When you are done, post it here, we all want to see!

Groovy! Thanks for your input. Oh, and we are WAY too small for a marketing department, but I am certain I can squeeze a few more colorful items on the page!

Please don't hold your breath waiting for me to post. It shall take a while to put the mapping together and all that jazz, but if this works out, I certainly will share! And I will keep looking for other feedback on my crazy idea (which was just a bunch of ideas I read here rolled into one).

Thanks to all!!

Mary :-P

Thank you so much, Don ... looking forward to hearing more from you.

Karin

Sadly, the organization that created it (an electronics mfg) is not in a sharing mood. I can describe it for you - 8 1/2x14 sheet, folded in thirds. One overleaf has the scope statement, the other overleaf the table of contents for their procedures manual. Unfolded, there's a process map, and not a particularly fancy one at that. I upoose technically that makes it a two page manual, but you could always use 11x17 paper....:)
DW

Sadly, the organization that created it (an electronics mfg) is not in a sharing mood. I can describe it for you - 8 1/2x14 sheet, folded in thirds. One overleaf has the scope statement, the other overleaf the table of contents for their procedures manual. Unfolded, there's a process map, and not a particularly fancy one at that. I upoose technically that makes it a two page manual, but you could always use 11x17 paper....:)
DW

That sounds neat but I can't see that ever working here -- but it's an ingenius idea for sure.

Karin

Oh, I like the table of contents idea. May have to borrow that one, too.

Thanks!

Mary

That sounds neat but I can't see that ever working here -- but it's an ingenius idea for sure.

Karin

Karin, Just curious. Why wouldn't it work.

It's regarding the training aspect provided in TS -16949.
What are extra competence requirements please, asked beyond ISO Y2K?

I am a teacher, and so enthused by TS 16949, and tempted to think why it should be limited to automotives. After all every thing is driven ( by right processes and culture).
thareja

:bigwave:
HI! Just wanted to thank everyone for their answers to my question. I finally paid the fee for the downloads, and am doing that now. I see a lot of new people, Welcome! Websites I have found helpful are: *** DEAD LINK REMOVED ***,
www.fasor.com, and *** DEAD LINK REMOVED ***, and finally for those who need it, *** DEAD LINK REMOVED ***. The last four cover lab and measurement uncertainty and measurement sys anal, (I keep a log of good websites). This is my contribution to help the many who help myself and others.

Manoj,

Can you pls. explain as to what exactly you mean by 'process maping'. An example would be very much appreciated.

Rakesh


Have you found any software that is easy to use for process mapping


Ramona

:bigwave:
No Ramona I have not. OOPS! Got caught for an audit in the middle of my reply.

Have you found any software that is easy to use for process mapping


Ramona

There are a couple of ways to do this. One is to use a regular flowcharting software, or perhaps something like Viseo. They will do the job, but the larger and more complex the processes, the less their effectiveness.

We have been discussing a software solution specifically for process mapping with the folks at I removed the name of the company . I know Dave (a different Dave) visits the board. There are several issues that must be worked out, and I'm not sure that the software can be created economically enough to allow an attractive price and sufficient profit for them. But based on their other software, if it can be done, Dave will figure out a way to do that.

:) Good Morning All! If I understand Process Mapping correctly, it is like making a flow chart like diagram of each process showing how each operation links together. Someone please correct me if this is not right.

WB,
Here's a flow chart of our overarching production process. Obviously, there are a lot of details missing because this covers 5 teams making 100s of different products. But that's the point, keep it short and simple (KISS). We have individual procedures for how to actually build and test each product and the detail and length of these vary by team and product.

:thanx: Thanks for your reply! The map is a good starting point. Piece by pieceI am putting it all together. I am definitely too wordy!

Hi Daman,
I would appreciate having a copy of your TS 16949 Quality Manual.
Thanks in advance Daman.
Wallace Tait

I have completed the TS 16949:2002 manual, and the auditor found no issues
on the documenation audit. The on site audit is Jan 12th. In the interest of sharing, i have attached some procedures here.

I have completed the TS 16949:2002 manual, and the auditor found no issues
on the documenation audit. The on site audit is Jan 12th. In the interest of sharing, i have attached some procedures here.

IDAY38....Hello fellow Naugatuckian. Looking at the Preventive Action Procedure, I see things like Preventive Maintenance, SPC, etc..There are those who would consider those "Preventive Actions" listed, required by other clauses. Hey, not me. I like it. :vfunny: One potential Registrar Lead Auditor also classified N/C's for a particular product that was extended to cover other product as "Preventive". That didn't go over big here with some of the members, either. What did you do for "Continuous Improvement"? Was that part of the Manual? :agree:

:thanx: 1day38! I will review and get back. In process of putting mine together in parts. Good Luck on your Audit! Look forward to hearing how it went. Merry CHRISTmas, Happy New Year! WEB

I can use copy and paste form my QM to let you know how I handled continuous imprvment.
" One of the major objectives of ITW Nutmeg is to foster continual improvement in all aspects of our business, with particular attention to customer satisfaction. Continuous improvement projects are identified though analysis of company and customer data reviewed at the management review meeting and corrective and preventive action on our product and processes. The responsible project manager uses the continuous improvement log to record the project, the goal, the status date, and outcome.
Everyone in the organization is encouraged to provide ideas for improving product, processes, and the working environment. Suggestions can be made to the appropriate management.
It goes on to par 8.5.1.1. ...................
Use of methods specific to our customers such as risk analysis, statistical studies, and measurement system analysis
Analysis of measurements and actions directed at improving customer satisfaction such as improving delivery, improving response time to customer communications, decreasing scrap, improving manufacturing effectiveness and reducing parts per million to achieve zero defects"

very intersestign that you are form Naugatuck too, is your company getting registeted to TS? I would love to hear from you.

:bonk: Igoofed up ! I answered the wrong post 1day 38. Sorry! I am not a nogatuckian. I hail from michigan, will be more careful next time. Merry CHRISTmas, Happy New Year ! to you and all the COVE FAMILY!
WEB

Help... I have just been given the task of writing all work instructions for a manufactured product that has just come out of R&D. Does anyone have any templates that I can use?
Thanks SASS :bonk:

I think if you look around the forums you may find what you are looking for. Several examples have been posted during the years. However, your request is odd. No other work instructions exist in your organization? Work instructions should take a format that suits your org, product, processes, etc. With this kind of open request, you'll have a hard time getting what you are looking for here without more detail.

Who, what, when (sequence) and how are the basics of any work instruction.

Typically, the equipment and processes used in R&D are completely different from those used in actual production, depending on the quantity of product to be manufactured.

There is an entire discipline known as production design and engineering which designs the processes and systems to manufacture an R&D product for commercial production, regardless whether the product is a widget, a complex machine, or a pharmaceutical.

As those processes and systems are designed,

then equipment allocated, leased, or purchased and
then employees are allocated or hired, and
then the production plans are broken down into steps or stages and
then work instructions are devised and written for each of those steps,
so employees can be trained for competency to perform the tasks.

If you have a relatively simple modification to an existing product, then all of the above steps are scaled back, but they are still covered in some way.

I have a hunch, though, you merely want to see some sample work instructions for "look and feel" so you can adapt your own to the model.

Thus said, here is a very average, but serviceable format at
http://www-project.slac.stanford.edu/glastqa/qadocs/WorkInstruct1.doc

Another one is at
http://ims.ivv.nasa.gov/isodocs/IVV_05-3.doc

In modern usage, though, most professionals recommend flow charts, cartoons, photographs, even videos to make the intended process clear to workers. This is the route I would take. If it seems too overwhelming, talk to the people who will have to actually follow these work instructions you're tasked to create and ask them what style will work best for them.

After you've had a chance to consider some of the comments posted here in the Cove, come back and ask us some more after you get that input from your proposed work instruction users. If all else fails, you can give us details about the product and the machinery and proposed process and we can give you some samples to get your creative juices working.

'SAFETY REQUIREMENTS' such as 'Personal Protective Equipments' required to do the work may be added, prior to start of actual 'Work Instructions' in the template

This is what I've got at the moment for my QMS Layout. Please let me know if this is good, bad or sufficient. I need an opinion beyond my Mgmt. Specifically I've got this in the flow as shown below. Does it make sense, is it intuitive to anyone else?

- Human Resources Mgmt. (i.e. Selection of employees, Job Descriptions.
- Product Development & Validation (RFQ, Contract Review, APQP, PPAP)
- Materials Management (i.e. Handling of Releases/Shipping, storage)
- Maintenance of Tooling & Equipment (i.e. Tooling & Inspection Equipment)
- Inspection & Testing (i.e. same as QS)
- Production Scheduling (i.e. Capacity Planning, scheduling)
- Control of Documents & Records (just what it sounds like)
- Product Realization (i.e. Set-Up & Work Inst., basically the making of the product)
- Internal Audits (i.e. product audits, TS audits, dock audits)
- Management Responsibility (i.e. Review, Business Planning)
- Continual Improvement (i.e.suggestion programs, kaizen)
- Control of NCP (i.e. containment, etc.)
- Corrective/Preventive Action (8D's, rework methods)

Thanks so much

Looks like oyu have covered the bases, but I would categorize them into the three recommended areas:

Customer-Oriented Processes COP (those that support the customer directly. Often referred to as the Core Processes, i.e.: Order-Build-Ship).

Support-Oriented Processes SOP (Those that support the COPs. i.e. HR, Maintenance, Improvement)

Management-Oriented Processes MOP (Those that support the business in general, i.e. Management Responsibility).

Hope this helps...

Thanks for the above. Specifically I was wondering if it's permissible to have Mgmt. Responsibility towards the end, below Internal Audits indicating the flow. I'm catching flak as the set-up doesn't match the flow of the standard, i.e. Documents first, etc.

Thanks

The way my flow is set up is the COPs are in order in the middle (left to right) then the MOPs and SOPs are in a circle (ok, rectangle) around that. MOPs and SOPs don't necessarily flow in line (the COPs do), they can happen almost any time and interact with multiple processes.

Who are you catching Flak from? Your auditor, or internal people?

You do not have to match the flow of the Standard (which isn't really a flow), in fact, I would recommend against it because it leads you down the elemental path, which is a no-no.

Here is an example of my Quality Manual (it folds like a brochure), which includes the flow:

Who are you catching Flak from? Your auditor, or internal people?

You do not have to match the flow of the Standard (which isn't really a flow), in fact, I would recommend against it because it leads you down the elemental path, which is a no-no.

Catching it from above. The feeling is that the AIAG knows best how to layout a manual, so ours should match the TOC.

Hmm. Well, good luck, and let us know what your auditor thinks.

Hi everyone,
I find this thread very helpful since I was just a beginner for the TS16949:2002 requirements.
Again, thank you for all who contribute on this thread.
Best regards,
Raffy :cool:

We are in the process of going from QS to 16949. I am also using a 2000 manual and adding the TS additional requirements. I would also like a copy of your manual when you have finished. I would just like to see the approach/format someone else has used. I would also be willing to share my manual when completed.
Hi Billie Griffin,
Saw your comments (dated Aug 2002).
We are also changing from ISO9002 to TS16949.
Our QM is about 200 pages in length, I sure would like to compare QM also to see the format and TS16949 approach.
We manufacture Bullbars.
Aussie.

Aussie, I'll attach one we developed with a little help from the Cove
From one "Old Dude" to another, hope this helps.
We have been TS16949:2002 Certified with this one.
Good luck

If I could get a copy It would be helpful to me too.

Hi,
Are you still looking for a copy of the Quality manual?
If so I can send ours thru.
Aussie

Hi Billie Griffin,
Saw your comments (dated Aug 2002).
We are also changing from ISO9002 to TS16949.
Our QM is about 200 pages in length, I sure would like to compare QM also to see the format and TS16949 approach.
We manufacture Bullbars.
Aussie.

200 page quality manual???? Mate that seems excessive...does it take in a few of your second tier documents (Quality Procedures)? I just could not imagine a manual that large..What other documents do you have (Work Instructions etc) and how large are they?

Thanks for the above. Specifically I was wondering if it's permissible to have Mgmt. Responsibility towards the end, below Internal Audits indicating the flow. I'm catching flak as the set-up doesn't match the flow of the standard, i.e. Documents first, etc.

Thanks


Supporting processes, like the ones you mentioned, don't generally flow from one to the next, like the main ones do. They are more like tools in a toolbox. You take them out as you need them to do a job.

Hi there,

My name is Sarah and I am new to this forum. I worl for an engineering company in essex, england. We are implementing TS at the moment. We are having trouble getting our heads round how complex the procedures have to be. Does anyone have an example of a calibration procedure so we can see how involved thet should be........any advice or help greatly appreciated

Hi everyone, :thanx:
First, I would like to thank again all those persons who shared their expertise and documents for TS16949. We are now in the process of TS16949 Certification by June 2007, I just hope that we would be certified by that time.
Thanks again.
Best regards,
raffy :cool:

Hi All,

Thank you for everyones contribution. It is much
appreciated.

Regards,

Stephen Pearce

:D