I can't answer them all, but here's the ones I can.
We did not combine any procedures. But be careful TS adds a requirement for a training procedure. CA and PA could be combined, but ths client implemented a very simple PA system.
This manual is new for the client. I following the new numbering system and referenced procedures, which is the basic philosophy I used for QS.
I have been audited to ISO - Y2k, so I'm following the same process mapping - with the added requirements where they fit. I don't think some fit well in our processes where they are in the standard, so the procedure references in the QM handle that.
Nope - haven't attended an AIAG course. I going on the fact that I've been in this game for awhile, passed ISO Y2K upgrades, and TS is just extra requirements. I do plan to attend. I guess its on the list for the fall sometime.
This particular client is not upgrading - they are going for it out of the chute - so I can't comment on upgrade costs. But your registrar should provide a quote. They are using NSF-ISR.