IATF 16949 6.1.2.3(e) Contingency Plan Testing

[KimGr]

Is anyone differentiating between Contingency Planning and Emergency Action Planning? It seems like many companies are combining the two. My read is Contingency Planning is more for continuity of business while Emergency Planning is reaction to life and death issues, natural disasters and environmental hazards. I'd appreciate anyone's feedback.

We are using the contingency plan as impact not specifically involving safety and using the EAP as a separate document. The subject matter, like fire, chemical spill, etc. is on both documents. EAP for safety. Once the employees are safe we move to the contingency plan for things like no production, missed work, environmental impact.

 

[Sebastian]

Testing of contingency plan starts from documenting contingency plan. When it is described in detailed manner, it is easier to develop and conduct testing. Especially when we want to do it in a reproducible way. When it is vague, it is up to contingency plan author's imagination, how to do it.
Maybe someone would share with us both elements, plan and testing evidence. Unfortunately I can't.

 

[darkmago]

I received a Non-conformance regarding this, we have been doing testing or simulation of almost everything. But the most difficult we find is Labour shortages, pretending people do not come to work. Any help on this? I am really worried about it.

 

[Golfman25]

I received a Non-conformance regarding this, we have been doing testing or simulation of almost everything. But the most difficult we find is Labour shortages, pretending people do not come to work. Any help on this? I am really worried about it.

I have no idea how you would effectively test "calling in a person from the other shift" without actually doing it. Do you have any experiences when you used a person on another shift to cover for someone? Maybe you can use that as "evidence" you plan could work. Or maybe a confirmation that you have the proper contact information to get in touch with the other people? But I'm sure this will make your company so much better. Good luck.

 

[AMIT BALLAL]

I received a Non-conformance regarding this, we have been doing testing or simulation of almost everything. But the most difficult we find is Labour shortages, pretending people do not come to work. Any help on this? I am really worried about it.

Brainstorm with your team to find out what can be done to fulfill the objective / test whether it can work when actually required.

I would at least simulate by calling second shift operators and tell them to come to first shift (Just to get their feedback, I won't want them to actually come). I would like to know their availability, problems and whether we need any extra resources in such situations (transportation facility, etc.).

 

[MJYoung]

I feel as though we can survive the audit on most of our easier issues like equipment or labor, but how are auditors dealing with fire or serious natural disasters. What kind of contingency plans could you have for a 100% loss of your facility?

 

[Golfman25]

I feel as though we can survive the audit on most of our easier issues like equipment or labor, but how are auditors dealing with fire or serious natural disasters. What kind of contingency plans could you have for a 100% loss of your facility?

IMO that contingency is on your customer. Not much you can do if you don't have duplicate facilities. Your customer really needs a plan to re-source the work at different alternatives. Google and read up about the fire that just happened last month to a supplier in Michigan.

Fire, explosions rip through instrument panel plant in Michigan

 

[Johnson]

Hello,

We handle "contiugency plan" as a part of the actions for "risk management process". The follow is abstracted from our procedure.


3.4.4 Contingency plans
As one form of risk treatment method, contingency
plans should be prepared to maintain product output
and ensure customer delivery, for the following but
not limited to the following events:
a) Facility/equipment failures and interruptions
b) Natural disasters, fires.
c) Supplier quality problem or material supply issue
d) Logistics and transportation issue
e) Delivery of non-conforming product to customer.
f) Lack of competent personnel
In case of contingency plans which may effect the
supply to customer, the customers must be notified
with the possible impact and it’s duration
The first piece product shall be validated when the
production is re-started after the contingency plan is
trigged.
The contingency plan shall be tested annually. Desk
top simulation and other options can be applied.
The management review the contingency plan once a
year.
The contingency plan shall be updated based on the
test and review result.
The contingency plan is put on the production site
and shall be accessible to all employees.

 

[Johnson]

Hello,

I attach a training material on IATF 196969 requirements on contingency plan testing, and how it can be done, from very simple method and complicated one.

The practice have been verified by the third part auditor.

Should you need further help, you may contact me.



Best Regards,
Johnson Shao

 

[Brizilla]

Attached where Johnson?