IATF 16949® Top Major Nonconformances in 2025

“Driving Automotive Quality Forward: Innovating and Elevating Standards,” was the theme at the 2025 AIAG Quality Summit, which was attended by simpleQuE Consultant, Paul Gambino. Hosted by the Automotive Industry Action Group (AIAG), the event explored how AI is reshaping automotive quality, and also addressed IATF 16949®, the Red Supplier Process, Measurement System Analysis (MSA), QMS audits, software quality, and more. In this and other articles Paul provides highlights and helpful insights for automotive suppliers. The focus of this article is the Top IATF 16949® Major Nonconformances and ways to resolve those issues. The simpleQuE infographic below illustrates the Top 10 Major and Minor IATF 16949® Nonconformances.

The International Automotive Oversight Bureau (IAOB), gave a presentation on the topic of, “Top NCs and what are we doing about it?” This initiative involves gathering data from the 19 IAOB certification bodies NC-CARA database for the clauses in question and conducting an analysis to the sub-clause level summarizing root cause results and corrective actions submitted by the organizations using AI tools. The focus is on the top 5 major nonconformance clauses as these are where IATF 16949®  certified organizations have the most problems and where the biggest risks to certification, customer satisfaction and quality performance occur:

1.  Problem Solving – 10.2.3 
2.  Nonconformity and Corrective Action – 10.2.1 
3.  Manufacturing Design Process Output – 8.3.5.2 
4.  Measurement Systems Analysis – 7.1.5.1.1 
5.  Control Plan – 8.5.1.1 

The top IATF 16949® sub-clauses were further examined and categorized.  For example:

10.2.3 f) – Reviewing and updating the appropriate documented information – accounts for 40.83% of the clause 10.2.3 nonconformances:

• Objective evidence cited included ineffective corrective actions and failure to update documentation such as pFMEAs and control plans.
• Root causes include inadequate training and competency, gaps in procedures and documentation, and lack of management oversight.
• Corrective actions included procedure updates, better assignment of responsibility and improved verification.

10.2.1 d) – Reviewing effectiveness of corrective actions – accounts for 60.45% of the clause 10.2.1 nonconformances:

• Objective evidence included implementation and follow-up gaps, inconsistent execution, no verification steps and/or unclear accountability.
• Root causes indicated weak monitoring and follow-up.
• Corrective actions recommended were action plan tracking through monthly meetings and management accountability to lead verification activities.

IAOB will be providing more details and resources for all five nonconformances on LinkedIn.  You can connect at: https://www.linkedin.com/company/international-automotive-oversight-bureau

IAOB provided these General Recommendations for all top nonconformance clauses (updated monthly on https://www.iatfglobaloversight.org/statistics/ )

1. Prioritize covering these clauses at each internal system audit
2. Strengthen Training Programs
3. Clarify Roles and Responsibilities
4. Improve Documentation and Procedures
5. Integrate System and Tools

 More AIAG Quality Summit highlights

Keep on track as Paul covers more interesting automotive quality topics and summaries in other simpleQuE blogs:

• What’s Ahead for IATF 16949® and Automotive Quality
• Catena-X and a Radical Collaboration Across the Automotive Industry
• How AI is Reshaping the Automotive Industry
• Measurement System Analysis – Going Beyond Audits

Paul Gambino, is a simpleQuE consultant and auditor with more than 20 years’ experience implementing, maintaining and improving automotive quality management systems and business processes. He is also currently an ISO 9001 and IATF 16949®  lead auditor for several Certification Bodies. 

Learn more about avoiding common nonconformities in our blogs with links to helpful videos:  

• IATF 16949 QMS Major and Minor Nonconformances and Common Root Causes
• The Top Major and Minor IATF 16949 WMS Audit Nonconformances of 2024
• Top IATF 16949® Audit Findings And How To Address Them In The QMS

SimpleQuE is a leader in AS, IATF® and ISO consulting, internal auditing, and training. Contact us for a consult and see the difference that our experts can bring to your quality management process.

SimpleQuE is not associated with the IATF®, IAOB, ANAB®, IAQG®, and is not a certification body. SimpleQuE is an independent ISO 9001 certified, consulting, training, and second-party auditing service provider that assists a company on a path for the company to obtain and maintain certification through accredited certification bodies.