TS 2nd revision TS

II phase 16949 :2002

revision of released
QS 9000
ISO 9000
released

I phase revision
First of ISO9000 :94
Fomation standard
of ISO- releaseISO
2002
Internatio 9000 2000
nal
Organisati 1999
on for
Standardi
zation
1994-1995
1994

1987
1995-96 ISO TS 16949 1999
released

1947
 TS 16949

QUALITY SYSTEM

REQUIREMENTS FOR

AUTOMOTIVE SUPPLIERS
 TS-16949

Aligns existing US, German, French ,

Italian,Japanese & English automotive quality
standards.

Aim is to create a single document & a single

third party registration that the European
automakers and the US big 3 would accept
 TS-16949

* Prepared by IATF (International Automotive Task

Force comprising of GM, FORD, DAIMLER
CHRYSLER & other national trade associations) in
the year 1999

* Harmonizes the requirements of the US big 3 and

French, German, English ,Japanese & Italian
Automakers

*Assisted by ISO TC/176 and its subcommittees

* Is still not an International Standard

* But Certifications for this TS is possible

 GOAL OF TS 16949

“Development of fundamental
quality systems that provide for
continual improvement,
emphasising defect prevention
and the reduction of variation
and waste in the supply chain”
INTRODUCTION OF THE

PROCESS MODEL
 THE PROCESS MODEL
MEANS

INPUTS PROCESS OUTPUTS

CUSTOMER ORGANIZATION CUSTOMER

PROCESS : CHANGE (= CONVERSION FROM INPUT INTO OUTPUT)

WHICH RESULTS IN AN INCREASE IN VALUE AND FOR WHICH MEANS
(RAW MATERIALS-MEANS OF PRODUCTION-PERSONNEL) ARE USED

FOR ORGANIZATIONS TO FUNCTION EFFECTIVELY, THEY HAVE TO

IDENTIFY AND MANAGE NUMEROUS INTERLINKED PROCESSES.

OFTEN THE OUTPUT FROM ONE PROCESS WILL DIRECTLY

FORM THE INPUT INTO THE NEXT PROCESS.
THE SYSTEMATIC IDENTIFICATION AND MANAGEMENT OF
THE PROCESSES EMPLOYED WITHIN AN ORGANIZATION
AND PARTICULARLY THE INTERACTIONS BETWEEN SUCH
PROCESSES IS REFERRED TO AS THE “PROCESS APPROACH”.
 THE PROCESS MODEL

THE WEB OF PROCESSES OF AN

ORGANIZATION

 AN ORGANIZATION MUST

DETERMINE, PLAN AND CONTROL

THE PROCESSES THEMSELVES,

THE SUCCESSION AND

THE INTERACTION AND INTERFACES BETWEEN THE

PROCESSES.
 PROCESS APPROACH MODEL
QUALITY MANAGEMENT SYSTEM
CONTINUAL IMPROVEMENT

C S C
Management a
u responsibility t u
i
R
s s s
e
f
q Measurement,
Resource a
t u analysis, t
management c
i improvement t
o r o
I
e
o
m
m e
n m
Product
n Input (and/or service) Output
e t Product/ e
realization Service
s
r r
Quality Management System

“PRODUCT REALIZATION IS THAT SEQUENCE OF ;PROCESSES AND

SUB-PROCESSES REQUIRED TO ACHIEVE THE PRODUCT”.
 FEATURES OF TS 16949

 Mandates timely review, distribution and

implementation of all customer Engg stds/specs and
changes based on customer reqd. schedules.
Organisation to maintain a record of the date on which
each change is implemented in production.
 Top management shall monitor the product
realization processes and the support processes to
assure their effectiveness & efficiency
 Top management shall define quality objectives
and measurements that shall be included in the
business plan and used to deploy the quality policy.
 FEATURES OF TS 16949

Quality-responsible personnel’s must have the

authority to stop production to correct quality
problems.

All production shifts to be staffed with personnel

responsible for quality

Customer Representative-Top Management shall

designate individual(s) to represent the needs of the
customer to address quality requirements.
 FEATURES OF TS 16949
MANAGEMENT REVIEW
5.6. MANAGEMENT REVIEW
OBJECTIVE = TO EXAMINE THE NEED TO ADAPT THE QMS, INCLUDING
THE QUALITY POLICY AND OBJECTIVES.
INPUTS :
* RESULTS OF AUDITS.
* CUSTOMER FEEDBACK.
* PROCESS PERFORMANCE AND PRODUCT CONFORMANCE.
* STATUS OF PREVENTIVE AND CORRECTIVE ACTIONS.
* FOLLOW-UP ACTIONS FROM EARLIER MANAGEMENT REVIEW.
* CHANGES THAT COULD AFFECT THE QMS
* ANALYSIS OF ACTUAL AND POTENTIAL FIELD FAILURES & THEIR IMPACT ON
QUALITY, SAFETY AND ENVIRONMENT
* COST OF POOR QUALITY
OUTPUT : ACTIONS RELATED TO
* IMPROVEMENT OF QMS AND ITS PROCESS.
* IMPROVEMENT OF PRODUCT.
* RESOURCE NEEDS.
 FEATURES OF TS 16949
COMPETENCE, AWARENESS & TRAINING
ASSIGNMENT OF PERSONNEL

EMPHASIS ON COMPETENCY AND PROFESSIONAL ABILITY OF

PERSONNEL BASED ON EDUCATION, TRAINING AND EXPERIENCE.

TRAINING, AWARENESS AND COMPETENCY

ORGANISATION SHALL HAVE DOCUMENTED PROCEDURES FOR

IDENTIFICATION OF NEEDS FOR TRAINING & COMPETENCY AND
THEIR ACHIEVEMENT

TRAINING ON THE JOB

ON THE JOB TRAINING TO BE PROVIDED TO PERSONNEL IN ANY

NEW OR MODIFIED JOB AFFECTING QUALITY INCLUDING
CONTARCT OR AGENCY PERSONNEL
 FEATURES OF TS 16949
EMPLOYEE MOTIVATION AND EMPOWERMENT
“shall have a process for motivation of employees to
achieve quality objectives, to make continuous
improvements, and to create an environment to promote
innovation .”

“The process shall include the promotion of quality &

technological awareness throughout the organisation.”

“shall have a process to measure the extent to which

its personnel are aware of the relevance and
importance of their activities and how they contribute
to the achievement of the quality objectives.”
 FEATURES OF TS 16949
INFRASTRUCTURE

PLANT, FACILITY & EQUIPMENT PLANNING

“Shall use multidisciplinary approach for developing plant,
facility and equipment plans”

“shall optimise material travel , handling and value added

use of floor space and shall facilitate synchronous material
flow.”

“Methods shall be developed and implemented to evaluate

and monitor the effectiveness of existing operations”
 FEATURES OF TS 16949
INFRASTRUCTURE

CONTINGENCY PLANS

“Organisation shall prepare contingency plans to

satisfy customer requirements in the event of an
emergency such as utility interruptions, labour
shortages, key equipment failure and field returns.”
 FEATURES OF TS 16949
WORK ENVIRONMENT
Personal Safety
“Product safety and means to minimise potential
risks to employees shall be addressed in the
supplier’s quality policy and practices especially in
design and development process and in
manufacturing process activities.”

Cleanliness of Premises
“The organisation shall maintain its premises in a
state of orderliness & cleanliness consistent with
the product.”
 BRIEF DEFINITION OF 5S
1S:

SEIRI
SEGREGATION

5S: 2S:
SHITSUKE
SELF DISCIPLINE
SEITON
5S SYSTEMATIC
ARRANGEMENT

4S:
SEIKETSU 3S:
CLEANLINESS SEISO
CLEANING
 OBJECTIVE OF 5S

1. UPGRADING THE IMAGE OF AN ENTERPRISE

2. IMPROVEMENT IN EFFICIENCY
3. SHORTENING OF LEAD TIME & ASSURING THE
DELIVERY TIME
4. REDUCTION OF STOCK
5. QUALITY UP GRADATION
6. ELIMINATION OF MECHANICAL FAILURE
7. SAFETY ASSURANCE
8. COST REDUCTION
9. ACTIVATING ORGANIZATION & BOOSTING OF
MORALE
 FEATURES OF TS 16949

CHANGE CONTROL

“SHALL HAVE A PROCESS TO CONTROL AND REACT TO CHANGES THAT

IMPACT PRODUCT REALIZATION.

THE EFFECTS OF ANY CHANGE SHALL BE ASSESSED , AND VERIFICATION

AND VALIDATION ACTIVITIES SHALL BE DEFINED, TO ENSURE
COMPLIANCE WITH CUSTOMER REQUIREMENTS.”

“CHANGES SHALL BE VALIDATED BEFORE IMPLEMENTATAION”

 FEATURES OF TS 16949

IDENTIFICATION OF CUSTOMER REQUIREMENTS

THE ORGANIZATION SHALL DETERMINE CUSTOMER

REQUIREMENTS INCLUDING :

a) PRODUCT REQUIREMENTS SPECIFIED BY THE

CUSTOMER, INCLUDING THE REQUIREMENTS
FOR AVAILABILITY, DELIVERY AND SUPPORT.

b) PRODUCT REQUIREMENTS NOT SPECIFIED BY

THE CUSTOMER BUT NECESSARY FOR
INTENDED OR SPECIFIED USE.

c) OBLIGATIONS RELATED TO THE PRODUCT,

INCLUDING REGULATORY AND LEGAL
REQUIREMENTS.
 FEATURES OF TS 16949

Organisation Manufacturing Feasibility

The Organisation shall investigate, confirm & document the
manufacturing feasibility of the proposed products in the contract
review process, including risk analysis

Customer Communication
Communication with customers in relation to :
A) Product Information.
B) Inquiries, Contracts Or Order Handling,
Including Amendments.
C) Customer Feedback, Including Customer
Complaints.
The Organisation shall have the ability to communicate necessary
information, including data, in a customer specified language and
format.
 FEATURES OF TS 16949

SPECIAL CHARACTERISTICS
“The organisation shall identify special
characteristics for design and development”

Special characteristics (Defn)- product characteristics

or manufacturing process parameters subject to
variation which may affect safety or compliance with
regulations, fit , function, performance or subsequent
processing of product.
 FEATURES OF TS 16949

MANUFACTURING PROCESS DESIGN INPUT

“The organisation shall identify, document and

review the process design input requirements
including:

-product design output data,

-targets for productivity,process capability and cost

-customer requirements, if any

-experience from previous developments”

 FEATURES OF TS 16949

MANUFACTURING PROCESS DESIGN OUTPUT

“The manufacturing process design output shall be

expressed in terms that can be verified and validated against
process design input requirements”

examples of process design output :

- specs and drawings
- work instructions
- process FMEAs
- results of error proofing activities
- methods of rapid detection and feedback of product/
manufacturing process non conformities; etc
 FEATURES OF TS 16949
Prototype Programme

“When required by the customer,the organisation shall have

a prototype programme.”

For this -
* Organisation shall use, wherever possible, the same
suppliers, tooling &manufacturing processes as will be used
in production.

* All performance testing activities are to be monitored for

timely completion & conformance requirements.
“While services may be outsourced, the organisation shall be
responsible for the subcontracted services, including
technical leadership.”
 FEATURES OF TS 16949

Incoming Product Quality

The organisation shall have a process to assure the quality of
purchased product utilising one or more of the following
methods-
Receipt of & evaluation of statistical data by the
organisation
Receiving Inspection and /or Testing such as sampling
Second or third party assessments or audits of supplier
sites.
Part Evaluation by a designated Laboratory
Another method agreed with the customer.
 FEATURES OF TS 16949

SUPPLIER MONITORING
Supplier performance shall be monitored through the
following indicators-
Delivered part quality performance
Customer disruptions including field returns
Delivery schedule performance
Premium Freights
Special status customer notifications related to quality or
delivery issues.
 FEATURES OF TS 16949

The Organisation shall develop control plans

Control Plan (Defn)-Documented Description of the systems for
controlling parts and processes to provide control of all
characteristics important for quality and engineering
requirements.
The control plan shall-
List the controls used for the manufacturing process control.
Include methods for monitoring of control exercised over special
characteristics
Include customer required information if any
Initiate the specified reaction plan when the process becomes
unstable or not statistically capable.
 FEATURES OF TS 16949

Work Instructions- “These Instructions shall be

accessible for use at the work station”

Verification of Job Setups- “Job setups shall be verified

whenever performed, such as initial run of a job, material
changeover, job change.”
 FEATURES OF TS 16949

PREVENTIVE AND PREDICTIVE MAINTENACE

The Organisation Shall identify key process equipment and provide resources
for machine/equipment maintenance.
The system shall include-
Planned maintenance activities
Packaging and preservation of equipment, tooling and gauging
Availability of replacement parts
Documenting , evaluating and improving maintenance objectives.

The organisation shall utilise predictive maintenance methods to

continually improve the effectiveness & the efficiency of production
equipment.
 FEATURES OF TS 16949

Production Tooling Management

The organisation shall establish and implement a system

for tooling management including:

* Maintenance & repair facilities & personnel,

* Storage & recovery
* Set up
* Tool change programmes for perishable tools
* Tooling identification defining the status, such as
production, repair or disposal
 FEATURES OF TS 16949

PRODUCTION SCHEDULING
Production shall be scheduled to meet customer requirements,
such as JUST IN TIME supported by an information system
that permits access to production information at key stages of
the process and is order driven.

FEEDBACK OF INFORMATION FROM SERVICE

A process for communication of information on service
concerns to manufacturing, engineering and design activities
shall be established and maintained.
 FEATURES OF TS 16949

Servicing agreement with the customer

“When there is a servicing agreement with the customer,

the organisation shall verify the effectiveness of:

* Any organisation service centres

* Special purpose tools or measurement equipment
* Training of servicing personnel”
 FEATURES OF TS 16949

VALIDATION OF PROCESSES
The organisation shall validate any processes for production
and service provision where the resulting output can not be
verified by subsequent monitoring and measurement.
This include any processes where deficiencies become
apparent only after the product is in use or the service has
been delivered.

IDENTIFICATION AND TRACEABILITY

THESE REQUIREMENTS HAVE BECOME
MANDATORY. i.e “Where Appropriate” phrases
removed
 FEATURES OF TS 16949

Inventory

“The organisation shall use an inventory

management system to optimize inventory turns
over time and assure stock rotation, such as ‘first
in first out’ (FIFO)”
 FEATURES OF TS 16949

MEASUREMENT SYSTEMS ANALYSIS (MSA)

“Statistical studies shall be conducted to analyse the

variation present in the results of each type of measuring
and test equipment system”
 FEATURES OF TS 16949

CONTROL OF MEASURING AND MONITORING DEVICES

-- An assessment of the impact of out of specification

condition is necessary.

LABORATORY REQUIREMENTS
An organisation’s internal laboratory facilities shall have a
defined scope that includes its capability to perform the reqd.
inspection, test or calibration services.
In case of inspections /tests carried out by external labs, apart
from having a scope, these external labs must also be accredited
to ISO/IEC 17025 standard or its national equivalent.
 FEATURES OF TS 16949

KNOWLEDGE OF BASIC STATISTICAL CONCEPTS

“Basic statistical concepts such as Variation, Control,

Process Capability and Over Adjustment shall be
understood and utilised throughout the organisation”
 FEATURES OF TS 16949

MONITORING AND MEASUREMENT

CUSTOMER SATISFACTION
“The Organisation shall monitor information relating to
customer perception as to whether the organisation has met
customer requirements.”
 FEATURES OF TS 16949

Manufacturing Process Audit

“The organisation shall audit each manufacturing

process to determine its effectiveness”

Product Audit

“The organisation shall audit products at appropriate

stages of production and delivery to verify conformance
to all specified requirements, such as product
dimensions, functionality, packaging, labelling, at a
defined frequency”
 FEATURES OF TS 16949

Internal Audit
Internal Audits shall cover all quality
management related processes, activities and shift

When internal/external non conformities or

customer complaints occur, the audit frequency shall
be appropriately increased.

The organisation shall have internal auditors who

are qualified to audit the requirements of this
Technical specification
 FEATURES OF TS 16949

MONITORING AND MEASUREMENT

Monitoring & Measurement of Manufacturing Processes

Conduction of process capability studies on all new manufacturing

processes & provide additional inputs for process control

Objectives and Acceptance criteria must exist for process capability,

reliability, maintainability

Initiate reaction plan for unstable & non capable processes, such as
100 % inspection

Subsequently , Initiate corrective action plans to assure that process

becomes stable and capable.
 FEATURES OF TS 16949

MONITORING AND MEASUREMENT

Monitoring & Measurement of Product

Monitor & measure the characteristics of the product to

verify that product requirements have been met.
 FEATURES OF TS 16949

LAYOUT INSPECTION
Layout inspection and a functional verification to applicable
customer engineering material and performance standards
shall be performed for all products at sufficiently frequent
intervals.

Layout Inspection (Defn)-A complete measurement of all part

dimensions shown on the design records.
 FEATURES OF TS 16949

APPEARANCE ITEMS
For appearance items provide-
Appropriate resources including lighting for evaluation
Masters for color, grain, gloss, metallic brilliance, texture,
distinctness of image as appropriate
Maintenance & control of appearance masters and
evaluation equipment
Verification that personnel making appearance evaluations
are qualified to do so.
 FEATURES OF TS 16949
CONTROL OF NON CONFORMING PRODUCT
Product with unidentified or suspect status shall be classified as non-
conforming product.

CUSTOMER INFORMATION
Customers shall be informed promptly in the event that non
conforming product has been shipped.

CUSTOMER WAIVER
The organisation shall obtain customer concession or deviation
permit prior to further processing whenever the product or
manufacturing process is different from that which is currently
approved.
 FEATURES OF TS 16949

CONTINUAL IMPROVEMENT- Continual Improvement

of the QMS through the use of

* QUALITY POLICY
* QUALITY OBJECTIVES
* AUDIT RESULTS
* DATA ANALYSIS
* CORRECTIVE AND PREVENTIVE ACTIONS
* MANAGEMENT REVIEW

MANUFACTURING PROCESS IMPROVEMENT

Continual Improvement shall focus upon control and reduction
of variation in products characteristics and manufacturing
process parameters.
 FEATURES OF TS 16949

PROBLEM SOLVING
The organisation shall have a defined process for problem
solving leading to root cause identification and elimination.

ERROR PROOFING
The organisation shall use error proofing methods in their
corrective action process

REJECTED PRODUCT TEST ANALYSIS

Parts rejected by the customer to be analysed and corrective
actions to be initiated to prevent recurrence.
 Stance of Major Auto Players
towards TS-16949
• GM requires its suppliers to upgrade to TS
16949 .

• NISSAN & HONDA recognised it.

• FIAT has mandated the standard in Europe

 Benefits of TS-16949
• Reduction of variance & increased efficiency
• Improved product & process quality
• Provide additional confidence in Global
sourcing
• Reduction in second party audits
• Common Quality System approach in the
supply chain for development & consistency
Thank you