IATF 16949 - Non-conformity on 5.1.1.2 Process effectiveness and efficiency

Andrei77

Starting to get Involved
#1
Hello everyone,

We have recently passed an IATF transition audit with a lot of minor NC and a few major NC as well.
One of the minors strikes me a bit awkward as I believe it is at the discretion of our management and leadership to chose what to measure and what not.
Of course, there`s a belief (true, in my mind) that what gets measured gets done, but why would an auditor single out some processes (engineering, design, calibration) for not having been measured with KPI`s?

Right now I am supposed to analyze all these non-conformities and their root cause/s and I am really struggling on answering Y`s on this one.

The NC is worded like this: "During the audit, it was found that the processes of engineering, calibration and design did not have any targeted KPI's assigned to them."

Any thoughts?

Thank you
 
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Golfman25

Trusted Information Resource
#2
It's been a long standing requirement in auto that all process have a kpi. It's kind of dumb because you can have a process you use infrequently that doesn't lend itself to kpi measurement. And as you say, it should be mgmt discretion. As for root cause there isn't one other than misunderstanding of the requirements. Good luck.
 
#3
I am having a similar issue with this clause and working to update our scoreboards before our recertification audit.

Our Internal Auditor wrote us a nonconformity for lacking both an effectiveness and an efficiency metric for each process. We already have metrics defined for each process (some with multiple metrics), but according to him they represent one or the other and there should be both.

In my opinion, if we are tracking metrics that make sense for each process that should be enough to conform? If a metric is not meeting target it is going to be a red flag to investigate.
 

Andrei77

Starting to get Involved
#4
Thank you very much everyone,

I really appreciate all your thoughts.
I did some research and I`ve found something which it might be interesting.
• The rate of New Product Introduction – Indicates how rapidly new products can be introduced to the marketplace and typically includes a combination of design, development and manufacturing ramp-up times.
• Engineering Change Order Cycle Time – A measure of how rapidly design changes or modifications to existing products can be implemented all the way through documentation processes and volume production.

Another idea that I wanna run by you is: where does it state that it has to be monitored monthly, it might be that some processes can only be monitored effectively on a semestrial basis or even annual.

Any thoughts?

Regards
Andrei P
 

Golfman25

Trusted Information Resource
#5
I am having a similar issue with this clause and working to update our scoreboards before our recertification audit.

Our Internal Auditor wrote us a nonconformity for lacking both an effectiveness and an efficiency metric for each process. We already have metrics defined for each process (some with multiple metrics), but according to him they represent one or the other and there should be both.

In my opinion, if we are tracking metrics that make sense for each process that should be enough to conform? If a metric is not meeting target it is going to be a red flag to investigate.
Your internal auditor is "correct." The standard says effectiveness AND efficiency. So you need one of each. They stared emphasizing it a few years ago. You can us the same metrics for multiple processes to keep you numbers in check. Good luck.
 

Golfman25

Trusted Information Resource
#6
Thank you very much everyone,

I really appreciate all your thoughts.
I did some research and I`ve found something which it might be interesting.
• The rate of New Product Introduction – Indicates how rapidly new products can be introduced to the marketplace and typically includes a combination of design, development and manufacturing ramp-up times.
• Engineering Change Order Cycle Time – A measure of how rapidly design changes or modifications to existing products can be implemented all the way through documentation processes and volume production.

Another idea that I wanna run by you is: where does it state that it has to be monitored monthly, it might be that some processes can only be monitored effectively on a semestrial basis or even annual.

Any thoughts?

Regards
Andrei P
There is no monthly requirement. Some will have enough data for monthly analysis, others will not. We do most on a quarterly basis.
 
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