Understanding and auditing IATF 16949 - Exide Technologies

Your email address:

Your name:

Company name:

Question 1 of 30

1. What was the purpose of IATF establishing IATF 16949?

To drive improvement in the automotive supply chain

As a tool to enable cost down by 5% per year

To compete with ISO 9001 as a global quality management standard for the automotive supply chain

To drive improvement in environmental performance

Question 1 of 30

Question 2 of 30

2. When preparing to audit in an organization in the automotive supply chain what would be the audit criteria:

ISO9001: 2015

Customer specific requirements

IATF 16949: 2016

All the above answers are correct

Question 2 of 30

Question 3 of 30

3. In IATF 16949 customer specific requirements are:

Interpretations of or supplemental requirements linked to a specific clause(s) of ISO14001

Interpretations of or supplemental requirements linked to a specific clause(s) of IATF 16949

Requirements relevant to a specific product

Additional health and safety requirements related to ISO45001

Question 3 of 30

Question 4 of 30

4. What is the IATF definition of automotive?

Cars, buses, trucks and tractors

Cars, buses, tractors and off-road vehicles

Cars, buses, trucks and motorcycles

Cars, bicycles, tractors and off-road vehicles

Question 4 of 30

Question 5 of 30

5. IATF 16949 structure is based on:

PDCA

CADP

DPCA

CDAP

Question 5 of 30

Question 6 of 30

6. IATF 16949: 2016 requires an organization to:

Identify its processes, their sequence and interactions

Identify procedures to address every clause of the standard

Identify all health and safety risks

Mandate that all their suppliers and sub-suppliers are IATF 16949 certified

Question 6 of 30

Question 7 of 30

7. The goal of IATF 16949 includes:

Continual improvement

Defect detection

Increase in variation and waste

All the above are correct

Question 7 of 30

Question 8 of 30

8. Employees working in an IATF 16949 certified organization need to:

Understand all requirements in IATF 16949

Understand any relevant procedures and instructions related to their job

Understand all the requirements of ISO14001

Understand that if they make mistakes they will be disciplined

Question 8 of 30

Question 9 of 30

9. Internal IATF 16949 Quality Management System audits:

Need to be undertaken on each manufacturing process on every shift

Verify that product meets the specific product requirements

Need to be undertaken on each management system process over a three-year calendar period

Need to be undertaken by qualified third-party auditors

Question 9 of 30

Question 10 of 30

10. IATF 16949 Quality Management system auditors need to understand:

How to audit procedures for compliance

The automotive process approach for auditing, including risk-based thinking

How to use measuring equipment used in the manufacturing process

A technical understanding of the manufacturing process to be audited

Question 10 of 30

Question 11 of 30

11. An IATF 16949 audit programme:

Shall be created annually and not changed

Shall be reviewed and, where appropriate, adjusted based on occurrence of process changes, internal and external nonconformities, and/or customer complaints

Shall ensure all processes in the quality management system are audited annually

Shall be created by the Quality Manager

Question 11 of 30

Question 12 of 30

12. The turtle diagram:

Is a useful tool to help in planning and undertaking an effective process-based audits

Is mandated by IATF 16949

Is an alternative process to carrying out an FMEA

Must be included in the audit report to be compliant with IATF 16949

Question 12 of 30

Question 13 of 30

13. When undertaking IATF 16949 audits it is recommended:

PDCA approach is used

CAPDo approach is used

DPCA approach is used

CDAP approach is used

Question 13 of 30

Question 14 of 30

14. In undertaking an effective audit, it is recommended to start with:

With who

With what

How

What results

Question 14 of 30

Question 15 of 30

15. In IATF 16949 a minor nonconformity definition includes:

A single observed lapse in following one item of an organizations management system

Any noncompliance that would result in the probable shipment of nonconforming product

A total breakdown of the system

A number of minor nonconformities against one requirement can represent a total breakdown of the system

Question 15 of 30

Question 16 of 30

16. A follow up audit is normally required when:

Minor nonconformities have been identified

Opportunities have been identified

Major nonconformities have been identified

Legal and regulatory requirements have been complied with

Question 16 of 30

Question 17 of 30

17. In IATF 16949 which of the following is correct related to product audit

Product audits must be undertaken for every product on every shift

Operator checks on the product, as specified on the control plan can be counted as product audits

Product audits shall be undertaken using customer specified approaches

Product auditors must be IATF 16949 qualified system auditors

Question 17 of 30

Question 18 of 30

18. According to IATF 16949 product auditors shall be competent in understanding:

The use of any relevant measuring and test equipment

The process approach to auditing including risk-based thinking

All requirements of IATF 16949

All of the above are correct

Question 18 of 30

Question 19 of 30

19. Useful guidance in undertaking product audit can be found in:

VDA 6.7

ISO9001

VDA 6.3

VDA 6.5

Question 19 of 30

Question 20 of 30

20. Product audits can be carried out:

On finished product

On semi-finished product

On components

All of the above are correct

Question 20 of 30

Question 21 of 30

21. Part 2: Practical application of the knowledge on the IATF 16949 audit process

Situation 1You are undertaking an IATF 16949 audit of a gear manufacturing process. You see in the PFMEA that a special characteristic has been identified related to hardness of a gear, part number 45360, and that hardness measurements shall be undertaken every hour and plotted on an individual and moving range SPC chart. You review the control plan and hardness is not identified as a special characteristic. In talking with the operator, he states only 1 part is checked per shift and recorded in a log book as stated in the control plan and work instruction. You see that there have been three recent customer complaints related to hardness issues of this product.

Based on this situation select which you think is the most appropriate statement of nonconformity:

The process of developing PFMEA is not fully effective

Hourly checks are not being undertaken to verify product hardness

The process for controlling special characteristics is not fully effective

3 recent customer complaints had been received related to hardness

Question 21 of 30

Question 22 of 30

22. Based on the situation which do you think is the most suitable IATF 16949 requirement to raise the nonconformity against?

8.3.3.3

8.3.4.3

8.5.1.5

10.2.4

7.5.3.2.1

Question 22 of 30

Question 23 of 30

23. Based on the situation which of the following should be recorded as objective evidence (pick one or more)

A product recall should be instigated for part number 45360

3 recent customer complaints have been received related to the hardness of part number 45360

The PFMEA stated hardness checks should be done hourly for part number 45360, but checks were being done once per shift

The operator machining part number 45360 was not competent

Hardness had been identified as a special characteristic in the PFMEA for part number 45360, but this was not identified in the control plan

Product 45360 was not being manufactured under a stable and capable manufacturing process as the Cpk level was less than 1

Results of the harness checks are not being recorded on the individual and moving range chart as required by the PFMEA.

Question 23 of 30

Question 24 of 30

24. Based on the situation which of the following do you think is correct in grading the finding:

A major nonconformity

An opportunity for improvement

A minor nonconformity

An observation

Question 24 of 30

Question 25 of 30

25. The person responsible for the issue informs you one week later that the problem has been fixed and he would like you to close the issue. He states that the issue was caused in engineering, where the person responsible for creating the PFMEA had not effectively communicated with the person responsible for the control plan. He states the control plan is now updated for part number 45360 and checks are being done on an hourly basis.

Which of the following statement(s) do you agree with:

The response is acceptable and no follow up audit is needed

The response is not acceptable as the methodology use to get to the root cause is not clear

The response is not acceptable as systemic corrective action has not been taken to prevent reoccurrence of the problem

The response is not acceptable as 1 week is too long to respond according to IATF 16949

In a follow up audit you would verify that the PFMEA and control plan are undertaken by a multidisciplinary team and there is an effective method of communicating the required controls from the PFMEA to the control plan

Question 25 of 30

Question 26 of 30

26. Situation 2You are undertaking an audit of the procurement and supplier development process. You are told there are 10 current suppliers of components and materials used in the production process. Out of the 10, 8 have ISO9001: 2015 certification, one is certified to IATF 16949 and one has no quality system approval. There was no evidence of any customer approval to use the supplier with no quality system approval.

You ask about supplier development. You are told no resource is available for undertaking supplier audits, and as such there is no planned development activities. You are told if there are any quality problems the supplier is informed and if necessary a quality engineer visits the relevant supply to resolve the issue.

The current supplier performance is 890ppm against a target of 100, and on-time delivery 89% against a target of 100%. You are told that this is not giving any problems and as such there is no action plan in place to address.

Based on this situation select which you think is the most appropriate statement of nonconformity:

Not all suppliers are certified to IATF 16949

The process of supplier development is not effective

Supplier performance target of 100% on time delivery not being met, currently 89%

Supplier target of 100ppm not being met, currently 890

The quality engineer is not competent

Question 26 of 30

Question 27 of 30

27. Based on the situation which do you think is the most suitable IATF 16949 requirement to raise the nonconformity against?

8.5.1.2

8.4.2.3

7.2.3

6.1.2.2

6.1.2.3

Question 27 of 30

Question 28 of 30

28. Based on the situation which of the following should be recorded as objective evidence (pick one or more)

Supplier performance target of 100% on time delivery not being met, currently 89%, no action plan

Not all suppliers are IATF 16949 certified

Supplier target of 100ppm not being met, currently 890, no action plan

One supplier being used was not certified to ISO9001: 2015 and no evidence of a customer waiver was available

No resources were available to undertake any supplier development activity

All product from the unapproved supplier was not being 100% checked

Question 28 of 30

Question 29 of 30

29. Based on the situation which of the following do you think is correct in grading the finding:

An observation

An opportunity for improvement

A minor nonconformity

A major nonconformity

Question 29 of 30

Question 30 of 30

30. The person responsible for the issue informs you two weeks later he has analyzed the issue.

He states the root cause identified, by using 5 why, is that there was an insufficient knowledge of the IATF requirements by the process owner.

He proposes the following actions to address the issue:

The supplier with no quality system approval has agreed to seek certification to ISO9001 within the next 3 months, a detailed timing plan was available.

An advertisement to recruit a supplier development engineer has been raised by HR and approved by management. Anticipated start date in 3 months.

An action plan has been created to address the shortfalls in supplier quality and delivery issues, will be monitored monthly as part of a procurement review meeting.

Which of the following statement (s) do you agree with:

The response is acceptable and no follow up audit is needed

The corrective actions proposed are not linked to the root cause identified

You would ask the process owner to keep you informed of progress of the actions and then schedule a follow up audit to verify the effective implementation os the actions proposed

You would ask what containment is being taken related to the product received from the supplier with no quality system approval

You would recommend the process owner attends an IATF 16949 lead auditor course to improve understanding

Question 30 of 30

Call Us: +44(0) 7341 845 930

Understanding and auditing IATF 16949 – Exide Technologies