Automotive Restart – Remaining Compliant to IATF 16949

Part 1 of our series focuses on automotive restart and the importance of remaining compliant to IATF 16949.  We begin with the 4 M’s of your processes and consider the IATF 16949 requirements during this restart process.

Materials:  The conventional wisdom indicates that supply chain disruptions will be evident during this restart activity (a few references include the Wall Street Journal article on April 26, 2020 “Coronavirus Supply Chains That Companies are Still Fixing” and Automotive News article on April 20, 2020 “Restart Rules”).  Your organization’s circumstances may vary greatly.  Nevertheless, the standard requirements need to be considered if the supply chain is disrupted or new suppliers are brought on board:

  1. IATF 16949 Section 8.3.4.4-PPAP and the customer’s approval of new suppliers
  2. IATF 16949 Section 8.4.1.2-supplier selection process
  3. IATF 16949 Section 8.5.6.1-change management
  4. Risk management considerations referenced throughout the standard

Methods:  Most likely changes to established methods will occur due to a number of factors, including reduction in customer volumes, reduction in headcount, change to process layout due to social distancing, etc.  When considering changing methods, the following standard requirements need to be considered:

  1. Risk management and mitigation of the revised process from previously approved processes
  2. IATF 16949 Section 8.3.4.4-PPAP and customer’s notification requirements of process changes
  3. IATF 16949 Section 8.5.6.1-change management
  4. IATF 16949 Section 8.5.6.1.1-temporary change management
  5. IATF 16949 Section 8.3.6.1-process or product design changes
  6. APQP output including FMEAs, Control Plans, work instructions, inspection instructions, etc.

Manpower:  The restart may introduce changes to your organization’s headcount and responsibilities of the employees.  There may also be changes to the organization’s policies and safe working practices (reference: Bloomberg article April 16, 2020 “Automakers Will Need Months to Get Factories Back Up and Running”).  If facing these challenges, please consider the standard requirements mentioned above, as well as:

  1. ISO 9001 and IATF 16949 Section 5 and Section 7-policies, responsibilities and authorities, competency requirements, process ownership changes, etc.

Measures: The restart will, more than likely, impact the original 2020 business planning goals and objectives established for your organization.  New goals, objectives, KPIs, metrics may need to be considered and established as a “new normal” settles into the industry.  When thinking about revising the organization goals, consider the standard’s requirements including:

  1. IATF 16949 Section 6.2.2.1-setting performance targets
  2. ISO 9001 and IATF 16949 Section 9-monitoring and measurement of process, customer satisfaction indicators, and reporting during management review

Part 2 of this series will include a discussion on maintaining customer satisfaction while working through the challenges of restart.

SimpleQuE strives to be an informational source that provides value to our customers by examining some of the challenges identified by the automotive industries and provide insight into the IATF 16949 requirements to help your organization maintain compliance during this unusual and complex time. 

This series of articles was written by Robert (Bob) Dornhecker, a simpleQuE consultant who specializes in ISO 9001 and IATF 16949 quality system development, auditing and training. He also performs third party audits for Certification Bodies including Eagle Certification Group. With over 30 years of combined experience in auditing, manufacturing and certification, Bob has an extensive quality background.  Additionally, he has taught and facilitated many quality related training classes for clients and has provided support to companies securing their own ISO/Quality Management Systems certifications.

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