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Example 2 of Major and Minor NCR - Calibration Problem

In auditing calibration, the auditor finds a gage that is out of tolerance (OOT) and there is no reaction to this OOT condition.

Example 3 of Major and Minor NCR - Past Due Preventative Maintenance

In auditing Maintenance, the auditor finds a few pieces of production equipment that are past due for PMs.

Example 4 of Major and Minor NCR - Leaking Storage Tank

This example occurred in a facility that contained 1,000 gallon holding tanks of oil and other chemicals used in the firm’s equipment and processes.

In auditing the chemical storage area, the auditor observed oil leaking from a tank to a grate which appeared to be flowing to a sewer outlet and perhaps to the municipal sewer system.

New Tool for IATF 16949 Audits

ASR Staff
January 2021

The IATF has mandated that all certification bodies begin using a new tool for IATF audit reporting and nonconformance management, called the Common Audit Report Application or CARA. This tool will standardize reporting across the industry. This means your report will look different, but more importantly, the process for answering nonconformances will change.

CARA NC Management Tool Instructions for Clients

The IATF CARA Application is intended to harmonize the audit report and NC Management processes. The CARA Nonconformity (NC) Management Tool is used to exchange the response between the Certification Body auditor and client to complete the relevant problem-solving steps related to the nonconformities issued during the closing meeting of the audit. It is mandatory for every IATF 16949 audit conducted by an IATF-recognized certification body.

IATF CARA NC Management Tool: (https://nc-cara.iatfglobaloversight.org)

Click here to download the instructions about using this tool.

Year 2020 IATF 16949 NC’s Written by ASR Auditors

Standardized (8.5.1.2) work instructions and visual standards (48) together with contingency (6.1.2.3) planning (37) were the top two nonconformances written by ASR’s IATF 16949 auditors during 2020. These numbers reflect on-site audits conducted before COVID-19 forced a large number of automotive suppliers to curtail operations.

IAOB OEM Red Supplier Program

The IAOB initiated the Red Supplier Program in 2019. This program disseminates OEM performance data to each Certification Body on a monthly basis for ASR to review against Customer Specific Requirements.

Currently only GM, Ford and PSA are participating but FCA will soon become part of the program as well, with other OEMs likely to follow. If ASR’s review of the performance complaint results in a suspension and subsequent special audit the IAOB has indicated, they plan to witness as many of these special audits as possible.

ASR covers the IAOB cost for all normal witness audits; however, the potential volume of these special audits in addition to our normal witness audits requires ASR to pass the cost of these witness audits resulting from a customer performance issue through to the client.

Challenges Face AIAG/VDA FMEA Users

By: Brandon Kerkstra – Guest Contributor
Management Solutions Group
March 2020

As automotive suppliers begin implementing the many features of the new AIAG/VDA FMEA Handbook, ASR invited Brandon Kerkstra to highlight in a three-part summary key FMEA changes found in this First Edition. Mr. Kerkstra is the founder of Management Solutions Group, a Grand Rapids, Michigan-based quality management system consulting firm.

Heads Up – New FMEA Roll Out

December 2019

AIAG and VDA have released their new joint FMEA Handbook to automotive suppliers. ASR’s automotive clients recently received an e/mail from our corporate office announcing the FMEA release.

The handbook is available for immediate use by Fiat Chrysler. Ford suppliers will be required to us the new FMEA format on a per program basis potentially starting with the 2022 programs.

Honda North America is accepting the AIAG & VDA FMEA format at any time, but on or about February 1, 2022 suppliers will be required to apply PFMEA for new production processes, lines, and parts. By January 2027, supplies are required to use the new format for all PFMEA documents.

General Motors plans to implement the new FMEA methodology with programs that start in 2023. GM is in the investigative stage of determining when they will start accepting FMEAs developed with the new FMEA Handbook. Auto suppliers can expect to see the transition roll out through GM’s customer specific requirements.

If you have questions regarding the new AIAG and VDA FMEA Handbook, reach out to ASR.

What’s Inside AIAG / VDA’s FMEA First Edition?

By: Brandon Kerkstra – Guest Contributor
Management Solutions Group
February 2020

As automotive suppliers begin implementing the many features of the new AIAG/VDA FMEA Handbook, ASR invited Brandon Kerkstra to highlight in a three-part summary the key FMEA changes found in this First Edition. Mr. Kerkstra is founder of Management Solutions Group, a Grand Rapids, Michigan-based management systems solutions firm.

IATF 16949 First Quarter 2019 Nonconformance Review

ASR is continuing its practice of sharing with clients the most frequent sections of the following standards found to be nonconforming by ASR auditors.

IATF 16949:2015 – Most Frequent Nonconformance’s:

9.3 Internal Auditing (22 NCs)

Total Productive Maintenance - Major Non Conformance Findings

As of October 2017, the top major findings were with Total Productive Maintance in the IATF 16949 certification audits.

IAOB released the top 10 major and minor IATF 16949 findings as of August 2017. Total Productive Maintenance ranked number two as a major finding, and number one as a minor finding.

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IATF 16949:2015 – Most Frequent Nonconformance’s:

9.3 Internal Auditing (22 NCs)

As of October 2017, the top major findings were with Total Productive Maintance in the IATF 16949 certification audits.

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