automotive auditor training

8/3/2019 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


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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1.2 Organization




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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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1.2 Organization




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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



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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.



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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;



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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.



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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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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


Audit Re ort


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SUMMARY COMMENTS

Company

Quality system specificities 2/


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)


Audit Re ort

MajorP /AFAQ AFNOR


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j

MinorPage: /


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


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) :


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 :


CERTIFICATIONAssessment Report


Audit Plan(Audit Preparation) 1/


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Audit Report(Audit Preparation)


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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Audit Report

Audit Plan(Audit Preparation)

2/


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 :


CERTIFICATIONAudit Report


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