Automotive Auditor Training
Transcript of Automotive Auditor Training
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Pierre DE GALZAINPSA Peugeot Citron Quality audit responsible
Khalil LACROIXAFAQ AFNOR Certification auditorISO/TS 16949
Auditors training
9th and 10th of April, 2005
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1. Context
2. Q631000 Standard
3. Audit guide & methods
Summary of training
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1. Context
2. Q631000 Standard
3. Audit guide & methods
Summary of training
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1.1 Bases of safety approval
1.2 Organization
1.3 Conditions for audit effectiveness
1. Context : Summary
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1.1 Bases of safety approval
1.2 Organization
1.3 Conditions for audit effectiveness
1. Context : Summary
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To ensure the capacity of safety parts suppliers
to deliver conforming parts
Purposes of safety approvalPurposes of safety approval
WhoWho??
Must obtain the approval :
each external supplier intending to provide safety
parts,
for each family of safety parts he would deliver.
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A generic standard, defined in the Q631000PSA standard,
Based on ISO standards, it focuses onrequirements which enable the supplier to
ensure the process stability.
Audit StandardAudit Standard
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Requirements of the StandardRequirements of the Standard Process qualification.
Modifications under control.
Supplier owing the right part definition (good
drawings).
Updated process control plan.
Effective monitoring of purchased parts.
Effective manufacturing process and controls.
Will and implemented organization to scrap everynonconforming part and to eliminate the non
conformity causes.
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Success conditionsSuccess conditions
The supplier must have an ISO/TS 16949 or ISO
9001 (version 2000) certificate.
The audit report does not mention any fact that
could affect the conformity of the product.
Parts measurements are in conformity.
The action plan solves every problem found by the
audit.
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3 possible conclusions after the audits3 possible conclusions after the audits
To refuse utilization of the suppliers parts :
Necessity to use CKD parts.
To accept utilization of suppliers partsunder condition of acceptance control by
IKCO.
To accept utilization of suppliers parts.
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Supplier calendarSupplier calendar
Safety approval is given after a complete audit
which proves that the supplier produces :
conforming parts,
with a stable production process,
Safety approval is valid for 3 years.
A yearly renewal audit must be done .
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Supplier calendarSupplier calendar
In case of refusal after the first audit :
Refused suppliers may ask for a second chance,
that can be planned at least 4 months after the
first one. It will be a complete audit. The auditors will also
have to check the effectiveness of the action plan.
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Safety approval does not change the
responsibilities sharing.
Safety approval notification is signed by
IKCO, SAPCO and PSA Quality Director.
Suppliers are responsible of the quality of the
parts that they deliver.
SAPCO & IKCO are responsible to managetheir suppliers.
ResponsibilitiesResponsibilities
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1.1 Bases of safety approval
1.2 Organization
1.3 Conditions for audit effectiveness
1. Context : Summary
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The committeeThe committee IKCO and PSA contribute in the Safety Approval
Committee :
including members of the Project, the Purchasing and
Quality departments that :
is endowed with a permanent secretary from PSA ;
will define the priorities for audits ;
will examine the AFAQ audit reports ;
will propose the suppliers to be approved to the
concerned directors.
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Audit teamAudit team
It includes 3 members :
an AFAQ auditor
a SAPCO auditor
a project team expert (optional)
A Lead Auditor
An Auditor
Part Expert
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Audit preparationAudit preparation
The SAPCOs auditor and Project team expert must
have studied before the audit, and take with them for the
audit : Drawings of parts
Technical specifications of parts
Control plan
Dossier of initial samples , conformity of actual
drawings and process
SAPCO and IKCO feedback about delivered parts
quality.
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Summary of training
1. Context
2. Q631000 Standard
3. Audit guide & methods
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A Control of the product, the process and
modificationsB Control of documents and data
C The suppliers purchases
D Product identification and traceabilityE Process and inspection
F Verification of measurement apparatus
G Control of nonconforming product. Corrective
actions
H Internal audits
Requirements of Q631000 StandardRequirements of Q631000 Standard
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The supplier defined a modification procedure ofproduct and process
Providing for qualification of the modified process.
Consistent with their client's rules for
manufacturing and for submitting initial samples.
The supplier does not transfer any production
without obtaining their client's written approval.
AA -- Control of the product, the processControl of the product, the processand modificationsand modifications
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The supplier applies a control and internaldistribution procedure for their client's
documents.
Data relating to the product and to the
associated processes is available to those who
need it.
BB -- Control of documents and dataControl of documents and data
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The supplier guarantees that the product
purchased from his sub-contractors is in
compliance with the requirements specified
by his clients.
The supplier measures the quality of the
purchased product and the performance of his
sub-contractors.
CC -- The supplier's purchasingThe supplier's purchasing
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The supplier carries out acceptance inspections at
frequencies and in accordance with sampling rulesthat are appropriate to the quality of the product
received from their sub-contractors and to the risks
relating to the product.
The supplier transmits to his sub-contractors data
that clearly describes the applicable specifications,
plans and special requirements, and keeps it updatedwith all modifications.
CC -- The supplier's purchasingThe supplier's purchasing
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At reception, during the production and at delivery,
the supplier applies rules for product packaging,identification and storage preventing any risk of
mixture of materials or components.
The supplier implements a traceability system
depending upon the size of the nonconforming lots
returned from the client with respect to the number
and characteristics of the faulty products delivered.
DD -- Product identification andProduct identification and traceabilitytraceability
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The supplier possesses a description of their
manufacturing process, including the product
inspections.
The supplier guarantees the compliance with the
quality level specified by the client by ensuring that: The installations he uses have the appropriate capabilities
to achieve the specified tolerances,
He complies with the rules communicated by the client to
calculate and verify these capabilities,
EE -- Process and inspectionsProcess and inspections
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Supplier implements a suitable monitoring
of the operating parameters of the equipments,
He carries out inspections and tests of the
product at frequencies and on samples
calculated according to the performance of the
equipments and to the results to be obtained.
EE -- Process and inspectionsProcess and inspections
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The supplier:
qualifies his manufacturing processes, trains and qualifies the operators and inspectors
in accordance with defined rules
makes the work instructions available to staffso that they have all the information required
to produce product that is in compliance;
EE -- Process and inspectionsProcess and inspections
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The supplier:
keeps an updated process log-book, in
accordance with defined rules, in which he
records, in particular, all failures, whether they
affect the product or the process, and the decisions
taken to correct them;
defines final inspection rules.
EE -- Process and inspectionsProcess and inspections
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The supplier complies with the rules
communicated to him by the client for the
verification of the measurement equipments usedfor the product or the process at the various
manufacturing stages.
FF -- Verification of measurementVerification of measurementequipmentsequipments
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The supplier separates all nonconformingproducts in secure boxes or closed areas.
He ensures that the nonconforming products are
identified either by labels or by permanentmarking. No nonconforming product must be seen
without its immediate and clear identification of
this status.
The supplier shall remove, daily, all rejected
products from the workshop.
GG -- Control of nonconforming productControl of nonconforming product& Corrective actions& Corrective actions
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The supplier shall assign qualified persons for
the regular analysis of nonconforming products,
undertakes, completes and records corrective
actions after every failure recorded by the client
and to eliminate the causes of the non-compliances
reported most frequently,
checks the effectiveness of these actions.
GG -- Control of nonconforming productControl of nonconforming product& Corrective actions& Corrective actions
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The supplier's schedule will include, in one or
more audits, all the requirements of this
Standard.
The audit reports are distributed to top
management, which regularly monitors the
progress of the necessary action plans.
HH -- Internal auditsInternal audits
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The Assessment ReportThe Assessment Report
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ASSESSMENT OF SAFETY PARTS SUPPLIER
STANDARD :
PSA Q631000SECURITY AGREEMENT OF EXTERNAL SUPPLIERS OF SECURITY PARTS
FOR MOTORCARS OF PSA PEUGEOT CITROEN GROUP
COMPANY
ADDRESS
Audit Date(s) :
Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CRTIFICATION, its assignees, is illegal
AFAQ AFNOR PSA Q631000
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AFAQ AFNORCERTIFICATION
Audit ReportSECURITY AGREEMENT
AUDIT REPORTName of the company :
Audit date(s) :Address of audited site (s) :
Activity concerned by the audit :
Reference of the part(s) concerned by the audit :
SUMMARY
Number of
sheets1. Cover page and summary
2. Comments memorandum of Lead auditor
3.1 New Major Nonconformance form(s)3.2 Major Nonconformance form(s)from the previous report (for additional audit)3.3 New Minor Nonconformance form(s)3.4 Minor Nonconformance form(s) from the previous report (for additional, follow
up or renewal audit)
Appendices summary :
A.1 Closing minutesA.2 List of main documents examined on siteA.3 Audit planA.4 On site inspection report
TOTAL
Name :
Function : E-mail:tact person of thedited Company
Telephone N: Fax N
AUDIT TEAM
Function Auditor name Date : Visa
uditor
r
Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal
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Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal
SUMMARY COMMENTS
Company
1/
Standard : Safety AgreementPSA Reference : Q631000
Part(s)Reference:Date:
General Conclusion :
- Characteristics, reference of the parts or sub assemblies inspected on site :
- Characteristics, reference of the parts sampled for testing by an independent laboratory
Documents and Data control
- Description of product inspection
- Design and development of products, if any; Product, process and modifications control
- Manufacturing process validation;
- Purchasing
AFAQ AFNORCERTIFICATION
Audit Re ort
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Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal
SUMMARY COMMENTS
Company
Quality system specificities 2/
Standard : Safety AgreementPSA Reference : Q631000
Part(s)Reference:
Reception of products and its inspection
Product identification and traceability
Production and inspectionroduct sam les to be measured in the su lier laborator then to be taken to the SAPCO laborator
Verification of inspection and measurement equipments
Control of nonconforming products
Corrective actions
Internal audits (if any)
AFAQ AFNORCERTIFICATION
Audit Re ort
MajorP /AFAQ AFNOR
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j
MinorPage: /
Standard : Safety AgreementPSA Reference : Q631000
Company :
1 THE NONCONFORMITY SUBJECT :
Does the nonconformity affect a safety characteristic :
NAME of Auditor : LA Signature : Requirement reference :
2 PROPOSED CORRECTION(S) AND/OR CORRECTIVE ACTIONS :
The organization must always give details of the corrective action even when a document which is the result of this corrective action is enclosed.
Target date : Name of the party responsible for action :
NAME of the organization representative : Signature : DATE :
3 COMMENTS CONCERNING THE ORGANIZATIONS ANSWER : Pertinent Non pertinent
NAME of the LA : Signature: DATE :
NONCONFORMITY MODIFICATION DECIDED BY THE SAFETY COMMITTEE : Date :............................................................................................................................................... Signature :
...............................................................................................................................................
Any reproduction or copy, whether whole or pa rtial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal
ORGANIZA
TION
ASSESSOR
LA
AFAQ AFNORCERTIFICATION
Audit Report
NONCONFORMITY N
CompanyAFAQ AFNORC C O CLOSING MEETING
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Standard :Safety AgrementPSA Reference : Q631000
Part(s)Reference:
LIST OF PERSONS WHO TOOK PART IN THE AUDIT CLOSING MEETING
NAME and first name FUNCTION SIGNATURE
Number of Major Nonconformities : Number of Minor Nonconformities :
Organization representatives comments :The organization representative acknowledges having read the content of the present report and the content of the major and /orminor nonconformities listed above and may mention his/her disagreement knowing that the Safety Accreditation Committee aloneis empowered to decide whether or not to grant the requested accreditation or its maintenance or renewal.
Date : Signature of the organization representative :
Audit team :Taking into account the documents presented, the installation inspected and the answers provided to the questions asked, theauditors declare, if such is the case, that they conducted their assignment under satisfactory conditions.The signature of the auditors in no case commits their personal responsibility or that of their employer in case of incidents, accidentsor errors committed by the organization after the certificate is awarded.
Date : Signature of the auditor(s) :
Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal
CERTIFICATIONAudit Report
CLOSING MEETING
DOCUMENTS REVIEWAFAQ AFNOR
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(partial audit preparation) Page: /
Standard :Safety AgreementPSA : Q631000
Company :
To be transmitted to the organization, to the audit team and to AFAQ AFNOR CERTIFICATION.
1 - COMMENTS ON EXAMINED DOCUMENTS
Listing of the documents & data available for the Lead Auditor :- name of the involved entities , - drawings of the manufactured parts (involve in the safety approval),- addresses and data of each involved entity - state of acceptance of Initial Samples (IS),- contact name within the organization, - technical specifications,
- supplier scope and involved product, - quality failure involving the supplier (given by Iran Khodro & SAPCO)- number of employees of the company,- control plan of the company,
2 - GENERAL CONCLUSION (Scope and limits, audit feasibility...)
LA signature : VISA : DATE :
Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal
CERTIFICATIONAssessment Report
AFAQ AFNORCERTIFICATION
Audit Plan(Audit Preparation) 1/
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Audit Report(Audit Preparation)
Standard :Safety AgrementPSA Reference : Q631000
Part(s)Reference:
The document review has been done. The assessment can be done yes no
LA signature : Date :Audit date:Company Name :Audited Site(s) :
Auditor(s) involved :LA :A :Observer :
Date/Hour
Chapter * Precise the audited site(s) name andConcerned chapter
AuditTeam
Audited Persons &Functions
4.1.2
4.1.1
4.1.3
4.1.5
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
Site:
Opening meeting
Site visit
Documents reviewControl of documents and data
Lunch
Design and development of products, if anyProduct, process and modifications control
Purchase
Reception of products and its inspection
Product identification and traceability
Production and inspection(product samples to be measured in the supplierlaboratory, than to be taken to the SAPCO laboratory)
Verification of inspection and measurement equipments
Control of nonconforming products
Corrective actions
Internal audits (if any)
Pre-closing meeting
Closing meeting
AFAQ AFNOR
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AFAQ AFNORCERTIFICATION
Audit Report
Audit Plan(Audit Preparation)
2/
Standard :Safety AgrementPSA Reference : Q631000
Part(s)Reference:
Date/Hour
Chapter * Precise the audited site(s) name andconcerned chapter
AuditTeam
Audited Persons &Functions
Date of the audit planning :
PROPOSAL FORM TO COMMITTEECompanyAFAQ AFNOR
CERTIFICATION
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(not to be included in the audit report but to be transmitted only to the committeeafter the audit has been conducted and organizations answer audit)
Standard : Safety AgreementPSA : Q631000
Part(s)Reference:
The LA, after agreement from the other auditors who took part in the present assignment andon the basis of the information gathered, suggests one of the following option to the CC :
AT THE CONCLUSION OF AN AUDIT : INITIAL
FULL RE-AUDIT
- delivery of security agreement
- organization of a full re-audit
AT THE CONCLUSION OF A
RENEWAL ADDITIONAL / UNDER CONTROL
OTHER Assessment (specify):
- Safety Security Agreement renewal (subsequent to a renewal audit)
- notification of a sanction (suspension - withdrawal - non-renewal)
Explanation of the proposal :
Any difficulties encountered in the interpretation of the reference standard, the application guide, if it exists, and/or in the contextof carrying out the audit have to be explained on page 3.
LA signature : VISA : DATE :
Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal
CERTIFICATIONAudit Report
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