Upon completion of this course, participants will be able to:

• Understand the relationship between IATF 16949, ISO 9001, and automotive core tools.
• Interpret and audit all IATF 16949 specific requirements and their intent.
• Effectively audit the application of key automotive core tools (e.g., FMEA, Control Plan).
• Assess compliance with specific customer-specific requirements (CSRs).
• Audit the processes for warranty management and product safety.
• Plan, conduct, and report process-based audits of a manufacturing system.
• Identify, classify, and write robust nonconformity statements related to IATF 16949.
• Evaluate the effectiveness of the corrective action process (e.g., 8D method).

• Quality Managers, Supervisors, and Engineers in the automotive supply chain.
• Internal and Second-Party (Supplier) Auditors for IATF 16949 organizations.
• Personnel responsible for implementing and maintaining IATF 16949.
• Individuals responsible for automotive core tools implementation and review.
• Consultants assisting in IATF 16949 preparation and auditing.
• Top Management seeking awareness of IATF 16949 risks.

• Case Studies based on real-world IATF 16949 audit findings.
• Practical Exercises in Auditing Control Plans and FMEAs.
• Group Activities focused on interpreting Customer-Specific Requirements (CSRs).
• Process Auditing Simulation using the Turtle Diagram approach.
• Role-Playing Interviews with production and quality personnel.

Unit 1: IATF 16949 Structure and Automotive Context

• Overview of the IATF 16949:2016 standard and its relationship to ISO 9001.
• Understanding the rules for certification and auditor qualification.
• Interpreting the automotive-specific clauses and their purpose.
• The importance of Customer-Specific Requirements (CSRs) in the audit process.

• Introduction to the Automotive Core Tools (APQP, FMEA, SPC, MSA, PPAP).
• Auditing the process for Product Safety.
• Auditing Risk Management, Contingency Planning, and Manufacturing Feasibility.
• Understanding the process approach, including Turtle Diagrams.

Unit 2: Auditing the QMS: Context, Leadership, and Support

• Auditing organizational context and top management commitment and leadership.
• Techniques for auditing Quality Policy and objectives.
• Auditing the competence and awareness requirements specific to the automotive sector.
• Auditing documentation, records, and control of documented information.

Unit 3: Auditing Planning and Operation

• Auditing the Planning process, including APQP deployment.
• Auditing Design and Development, focusing on input and verification/validation.
• Techniques for auditing Control Plans and Product Approval (PPAP).
• Auditing the external provider (supplier management) process and controls.

Unit 4: Auditing Production and Performance Evaluation

• Auditing Production Part Approval Process (PPAP) effectiveness.
• Auditing Production Control (e.g., setup verification, visual aids).
• Auditing measurement system analysis (MSA) and statistical process control (SPC) implementation.
• Auditing the warranty management and customer complaint processes.

• Auditing the internal audit program structure and effectiveness.
• Evaluating nonconforming product control and corrective action processes (e.g., 8D).
• Techniques for auditing management review inputs and outputs.

Unit 5: Auditing Core Tools in Depth

• Practical auditing of Failure Mode and Effects Analysis (FMEA).
• Practical auditing of Measurement System Analysis (MSA).
• Practical auditing of Statistical Process Control (SPC) usage.
• Developing audit trails focused on specific CSRs.