Permissible Exlcusions - Clause 7.3
Iday, take a good look at clause 1.2 of TS 16949:2002 (TS2) and the "IATF Guidance to ISO/TS 16949:2002", clause 7.3. The only clauses that can be excluded in their entirety is 7.3.2.1 (Product design input) and 7.3.3.1 (Product design output). All the other requirements of clause 7.3 are applicable to the design and development of an organization's manufacturing process. This includes 7.3.2 (Design and development inputs) and 7.3.3 (Design and development outputs), where the expectation is that one should substitute "Process" for "Product" in the ISO clauses.
Manufacturing process design CANNOT be excluded. This is clearly spelled out in clause 1.2 of TS2, and emphasized in the note under clause 7.3. Tool design cannot be excluded either, as tooling design clearly has a significant impact on the manufacturing process.
Take heart though - documented procedures are NOT required, but you are expected to comply with your customer's requirements for quality planning and product approval.
Hope this helps, and good luck on your transition efforts!
Don Wood
Deosil Management
Licensed Plexus Trainer/ ISO/TS 16949:2002 CB Auditor Examiner