A TS 16949 Implementation through Registration Project Diary - Automotive

[tomvehoski]

On the consultant/contractor issue, I have been in both positions.

As a consultant, I was told during TS audits that I could not participate, talk, sneeze, etc. The auditor was very strict on this. I chose to remain off-site most of the time. The issues that came up were called into me, I gave my client guidance on response/challenges, and they communicated it to the auditor. One issue that could have been resolved by me in person in 2 minutes took hours, so I am not sure what was gained, but I followed the "rules". I have had other audits (mostly 9000) where I was given the same warning up front, but once the auditor realized I was not going to try to control the audit - only clear things up if things went off track - they were fine with me participating a bit. Truly, if my client was struggling to answer questions they should have known, I let them struggle.

I am now a contractor with my current company. I don't work for anyone else, but am technically not an employee. I did participate in our TS upgrade audit with no objections at all from the auditor. Truthfully I don't know if he realized I was a contractor - I don't remember if I volunteered that fact or not.

I would recommend that if you want your consultant to participate, put him on the org chart as a contract employee. Have a clearly defined job description for the activities he performs. How he gets paid should not matter. Avoid the use of the term consultant and you should be OK.

Tom

 

[The Taz!]

I would recommend that if you want your consultant to participate, put him on the org chart as a contract employee. Have a clearly defined job description for the activities he performs. How he gets paid should not matter. Avoid the use of the term consultant and you should be OK. Tom

Good advice. . . I'll be facing this same dilemna soon. . . I've been introduced to the auditors during a QS surveillence audit, and they insisted on calling me a consultant even though we assured them I was a contractor there to help the cpmpany out in transitioning. Heck. . . I've done a heck of a lot more typing of procedures than consulting here. . .

 

[Icy Mountain]

That's why I love the Cove!

@tomvehoski
Our Contracted Internal Auditor appears on our Org Chart. He has a clearly defined job description as Internal Auditor. He will be partcipating in the Assessments, representing the Internal Audit Function. Our folks will answer the rest of the questions.

@sam
Our contracted internal auditor is certified and has represented other clients in both 9k2k and QS9k. He is currently working on his TS certification. We are in the process of selecting a CB. He has successfully operated this way with two different registrars and I am comfortable with both. We will talk to them about this situation...good advice.

@db
Thanks for the vote of confidence. If this was 9k94 I'd be OK. I am getting updated to the 9k2k "process approach" to auditing and the QS/TS automotive way of doing things. There's always something new to learn, especially if it's in a nice hotel in another city.

 

[Icy Mountain]

Back on the rails...Alllll Aboard!

I'd like to keep a running project progress log in this thread. Just a kind of how we did it. I'll be limited in what I can attach since much of the documentation will be paid work vs. my leisure time manual writing. Here goes:

First and second meetings:
Agreed on a Procedures Manual (a condensed and combined version of my regurgitated TS quality manual and our company specific quality assurance procedures) format, blank form format, blank job descriptions format, online manual heirarchy (where all these electronic files will be located and what the folder names are), how to keep each other updated, and finalized the Control of Documents section (TS16949:2002, 4.2.3) so that we can review and approve all of this stuff as we do it. I produced first rev job descriptions for Mgmt. Rep., Doc Administrator, and Quality Manager, since they have responsibilities in COD as well as revising the ECO form. All of this will go thru the Engineering Change Order process this week as identified in COD. I combined and condensed the old manuals into the new format. Consultant wrote first revs of sections 1, 2, and 3.

This week:
Worked on Training (6.2.2). Consultant writing procedure based on our process. Identified several supporting records that need to be revised and released for use, we are revising our training requirements lists with references (e.g. If I'm doing ESD Mitigation Training, where's the Level III procedure) and signoff approval spaces.

Next week:
Improvement (8.5) so that we can capture everything we do from here on since it will ALL be an improvement initiative.

 

[Icy Mountain]

Train keep a rollin'

Last week, completed initial Training on QMS-Control of Documents, just for those initiating and processing changes. All changes go through the newly released procedure from now on. Nothing special except that everyone is now using the exact same ECO form. Training will get wider as we release the whole QMS section.

Today, company-wide TS16949:2002 Awareness Training. 60 slide powerpoint presentation on Quality History and the general specifics of ISO9000/TS requirements. About an hour and a half with a Management Committment Introduction and Question and Answer session. This is my work so I'll strip the Logo off and post it if anyone's interested.

[Edit:]
This PowerPoint presentation is posted in the thread:
ISO/TS16949 Awareness Training Powerpoint.

 

[Icy Mountain]

I'm Aghast at the gap!

So long without an update...well, sometimes that's how projects start.

Today we formalized the implementation team (in order to get everyone's buy in that they will attend team meetings, it's a good idea to put their name on the team list). First team minutes and action items went out per our Team Based Organization communication structure (more about this later when we get to internal communication)

We are reviewing procedures for Training, Awareness and Competency and the associated records. Due for release next week. We also just handed out procedures for Measurement, Analysis and Improvement, specifically Continual Improvement, Preventive Action and Corrective Action and the associated logs/record keeping. We will review and discuss with our contract employee next week as well.
-Icy

 

[Icy Mountain]

Next

First team meeting with members from every department. Some minor review involved to get them up to speed.

Reviewed and released the Resource Management section. Specifically, Training, Awareness and Competency. A person specific and deparmental log for training are included as forms/records. Changed the person responsible for records update/retention from HR to Document and Data Control so that we don't have to invade personnel files during TS audits (our HR person deals with salary/fringe benefits/vacation/attendance and is not involved in training/hiring/job placement).

We are generating Job Descriptions (2 per department) at the Department Manager and Department Associate levels (due next week). Person specific training requirements will be developed and documented from there. Need to talk about grandfathering current employees but the team was happy to generate and sign a training record for every employee (probably a good idea, I bet we've missed a few items for a few employees).

Reviewed the Measurement, Analyis and Improvement Section. Specifically, Continual Improvement, Preventive Action, and Corrective Action. The procedures look good but we want to cut back from the contract employee suggested CI/PA/CA spreadsheet log, CI paper form, PA paper form, and CA paper form (on three different colored papers). More our speed is an Access database (with one form) of all three with a log integrated (I can write that in two hours, for example, I spent ONE day creating a relational database for FMEAs that prints on two different customer required formats. We pull the database up on laptop/projector and fill in FMEAs, online, as a team and only print for PPAP files).

Team Meeting with contract employee tomorrow to discuss MAI section.

 

[Icy Mountain]

Mai

Released the Resource Management Section of the Procedures.

Discussed MAI - CI, PA, and CA. Some minor tweaks for simplification (see last post). Database development underway. We'll review this and release next week along with the Job Descriptions.

Next issues: Control of Nonconforming Product, Process Measurement, and Analysis of Data. This is to begin driving the CI/PA/CA system so we can start capturing data to prove effectiveness.

 

[Icy Mountain]

Meeting last Thursday, released the Measurement, Analysis and Improvement Section with only the Improvement portion documented. Access database for tracking with ONE form, and an automated reporting log.

Reivewed the Job Descriptions, will be released this Friday along with a Training Attendance Form (how did we miss that?).

Starting on the rest of MAI this week.

 

[Icy Mountain]

Conference call with our contractor today. Discussed our methods for dealing with nonconforming material. We should have the nonconforming section ready for review at this week's meeting. Our current procedures are compliant, we just need to document, train and then DO IT.