I answered an PM on this same subject with the following:
My best advice: ask your questions at the Cove. There are many experts here and you will get multiple opinions.
If you already have a QS system, I recommend using the vast majority of it to meet TS2. Get some of the transition papers from ISO9k94 to ISO9K2k (http://qualitypress.asq.org/iso9000/
) (search on "transition") and QS9000 to TS16949 (CQI- 7: ISO/TS 16949:2002 Implementation Guide http://www.aiag.org/committees/cqsc.cfm#cqscpub
) and all the standards that you need (http://www.aiag.org/publications/quality/dcxfordgm.cfm
Start by identifying what you already have in your 9k94(or9k2K)/QS9k system that will satisfy 9k2k and TS2. From there, figure out the additions/changes that you will need to implement.
Rewrite your manual and eliminate the numbers; concentrate on writing a book that flows through your system. Process interactions and flows are the big buzzwords for TS. Train on the existing stuff. Then train on the new. and train. and train.
I created a spreadsheet with every section of TS2 listed down the left column. Note the numbers or titles of your existing manual sections that will support each TS2 section. Note the name of your new manual section. Track references and supporting forms and records for each section. Create a column for training, is it done? Who got it? Have an action item column, is the section written, implemented, trained, audited, effective, etc. Who's assigned to do what.
Guess what, after you do all that, you'll have a nice interaction of processes map. (sample attached)