Mitra matra iatf 16949 honda module 6

IATF 16949:2016 Honda – COACHWORKS –REVISION 0
Copyright 2020 © DWI
IATF
16949:2016
AUTOMOTIVE QUALITY MANAGEMENT SYSTEM

Hi..!
Saya, Danang
2
Senang, Kembali bisa menyapa
dan berbagi Bersama anda
kembali
• Saat ini saya masih bekerja di SGS Indonesia.
• Menjadi IATF Auditor sejak 2004
• Sebelumnya saya bekerja di Astra Daihatsu Motor
- dari tahun 1995 -2003
• Memiliki Six Sigma Master Black Belt tahun 2001
• Pernah bekerja di Dirgantara Indonesia (IPTN)
untuk proyek N250 : tahun 1992 – 1995.

AUDIT
Automotive quality management system

AUDIT
• 1st., Party audit > Internal Audit
• System Audit
• Process Audit
• Product Audit
• Dilakukan oleh auditor berkompeten,
direncanakan dalam bentuk siklus – 3 tahunan
• 2nd., Party Audit > supplier audit
• System, Product & Process
• Dilakukan oleh auditor berkompeten
• Direncanakan sebagai bagian dari
pengembangan supplier

AUDIT
• Tujuan 1st., party audit tidak sama
dengan 3rd., party audit
• 1st., party audit bukan untuk Persiapan
3rd., party audit

AUDIT
INTERNAL QUALITY AUDIT
LINKAGE
WITH CONTINUAL
IMPROVEMENT

AUDIT
Perencanaan & Pelaksanaan

AUDIT
Perencanaan & Pelaksanaan
Internal audit (9.2)
The organization shall conduct internal audits at planned intervals to provide
information on whether the quality management system;
a) conforms to:
1) the organization’s own requirements for its quality management system;
2) the requirements of this International Standard;
b) is effectively implemented and maintained.
• Perhatian dan komitmen manajemen : Bagian dari business strategy
perusahaan – dan proses evaluasi perusahaan
• Sasaran mutu yang terukur dari program audit mutu internal – sehingga
sebagai proses program akan dilaksanakan secara efektif dan efisien.
• Program harus disesuaikan dengan alamiah dari organisasi dan proses,
fungsi-fungsi dan proses –proses yang digunakan, tingkat kerumitan
serta tingkat implementasi dari sistem yang ada. Serta untuk hal-hal
penting, utama serta pertimbangan resiko dari rangkaian proses
tersebut.

AUDIT
Perencanaan & Persyaratan
Internal Audit (9.2)
The organization shall:
a) plan, establish, implement and maintain an audit programme(s)
including the frequency, methods, responsibilities, planning
requirements and reporting, which shall take into consideration the
importance of the processes concerned, customer feedback,
changes impacting on the organisation, and the results of previous
audits;
b) define the audit criteria and scope for each audit;
c) select auditors and conduct audits to ensure objectivity and the
impartiality of the audit process;
d) ensure that the results of the audits are reported to relevant
management;
e) take appropriate correction and corrective actions without undue
delay;
f) retain documented information as evidence of the implementation of
the audit programme and the audit results.

AUDIT
9.2.1 Please refer to ISO 9001:2015
9.2.2 Please refer to ISO 9001:2015
9.2.2.1 Internal audit programme
◦ Documented internal audit process
◦ Covers the entire quality management system including quality management
system audits, manufacturing process audits, and product audits
◦ prioritized based upon risk, internal and external performance trends, and
criticality of the process(es)
◦ Where the organization is responsible for software development, the
organization shall include software development capability assessments
◦ The frequency of audits shall be reviewed and adjusted based on occurrence
of process changes, internal and external nonconformities, and/or customer
complaints

AUDIT
9.2.2.2 Quality management system audit
The organization shall audit all quality management system processes over
three-year audit , according to an annual programme, using the process
approach to verify compliance with this Automotive QMS Standard. Integrated
with these audits, the organization shall sample customer-specific quality
management system requirements for effective implementation.
The complete audit cycle remains three years in length. The quality
management system audit frequency for individual processes, audited
within the three-year audit cycle, shall be based upon internal and external
performance and risk. Organizations shall maintain justification for the
assigned audit frequency of their processes. All processes are required to
be sampled throughout the three-year audit cycle and audited to all
applicable requirements in the IATF 16949 standard, including ISO 9001
base requirements, and any customer-specific requirements.

AUDIT
9.2.2.3 Manufacturing process audit
◦ The organization shall audit all manufacturing processes over each three-year
calendar period to determine their effectiveness and efficiency using
customer-specific required approaches for process audits. Where not defined
by the customer, the organization shall determine the approach to be used
◦ Within each individual audit plan, each manufacturing process shall be audited
on all shifts where it occurs, including the appropriate sampling of the shift
handover
◦ The manufacturing process audit shall include an audit of the effective
implementation of the process risk analysis (such as PFMEA), control plan,
and associated documents
9.2.2.4 Product audit
◦ The organization shall audit products using customer-specific required
approaches at appropriate stages of product and delivery to verify
conformity to specified requirements
◦ Where not defined by the customer, the organization shall define the
approach to be used

AUDIT
8.4.2.4.1 Second-party audits
The organization shall include a second-party audit process in their
supplier management approach. Second party-audits may be used for the
following:
a) Supplier risk assessment
b) Supplier monitoring
c) Supplier QMS development
d) Product audits
e) Process audits
8.4.2.4.1 Second-party audits, continued
o Based on a risk analysis, including product safety/regulatory
requirements, performance of the supplier, and QMS certification level,
at a minimum, the organization shall document the criteria for
determining the need, type, frequency, and scope of second-party
audits
o The organization shall retain records of the second-party audit reports
o If the scope of the second-party audit is to assess the supplier’s
quality management system, then the approach shall be consistent
with the automotive process approach
o NOTE: Guidance may be found in the IATF Auditor Guide and ISO
19011

AUDIT
Kompetensi Auditor

AUDIT
1st., Party Kompetensi Auditor
The organization shall have a documented process(es) to verify that internal
auditors are competent, taking into account any requirements defined by
the organization and/or customer-specific requirements. For additional
guidance on auditor competencies, refer to ISO 19011. The organization shall
maintain a list of qualified internal auditors. Quality management system
auditors, shall all be able to demonstrate the following minimum
competencies:
a) understanding of the automotive process approach for auditing, including
risk-based thinking;
b) understanding of applicable customer-specific requirements;
c) understanding of applicable ISO 9001 and IATF 16949 requirements
related to the scope of the audit;
d) understanding of applicable core tool requirements related to the scope
of the audit;
e) understanding how to plan, conduct, report, and close out audit findings.
7.2.3 Internal auditor competency

AUDIT
7.2.3 Internal auditor competency
• At a minimum, manufacturing process auditors shall
demonstrate technical understanding of the relevant
manufacturing process(es) to be audited, including process
risk analysis (such as PFMEA) and control plan.
• At a minimum, product auditors shall demonstrate
competence in understanding product requirements and use
of relevant measuring and test equipment to verify product
conformity.
• If the organization’s personnel provide the training to
achieve competency, documented information

AUDIT
Pengetahuan dan keterampilan generik
Auditor Sistem manajemen mutu :
• Pengetahuan dan keterampilan
generik auditor system manajemen
mutu
• Pengetahuan dan ketrampilan
spesifik
• Pengetahuan dan ketrampilan
tambahan yang dibutuhkan untuk
memimpin tim audit

AUDIT
Pengetahuan dan keterampilan generik
Auditor Generik:
• Prinsip, prosedur dan metode audit
• Sistem manajemen mutu
perusahaan dan dokumen acuan
• Konteks organisasi
• Persyaratan pelanggan, peraturan
dan perundang-undangan terkait
dengan produk dan proses yang
dilakukan

AUDIT
Disiplin ilmu dan pengetahuan serta
ketrampilan sector spesifik untuk auditor
system manajemen
• Fundamental disiplin dan aplikasi bisnis
serta metode spesifik disiplin teknis,
teknik, proses dan praktek
• Pengetahun disiplin spesifik terkait pada
sector tertentu
• Prinsip manajemen resiko
• Persyaratan pihak berkepentingan yang
relevan pada disiplin ilmu spesifik
• Ketrampilan spesifik terkait peraturan
dan regulasi terkait
• Spesifik keahlian untuk persyaratan dan
prinsip system manajemen

AUDIT
Pengetahuan dan ketrampilan
spesifik auditor
• Pendidikan
• Pengalaman Kerja
• Pelatihan auditor
• Pelatihan teknis
• Pengalaman Audit

AUDIT
2nd., Party Kompetensi Auditor
7.2.4 Second-party auditor competency
The organization shall demonstrate the competence of the auditors
undertaking the second-party audits. Second-party auditors shall meet
customer specific requirements for auditor qualification and demonstrate
the minimum following core competencies, including understanding of:
a) the automotive process approach to auditing, including risk based
thinking;
b) applicable customer and organization specific requirements;
c) applicable ISO 9001 and IATF 16949 requirements related to the scope
of the audit;
d) applicable manufacturing process(es) to be audited, including PFMEA
and control plan;
e) applicable core tool requirements related to the scope of the audit;
f) how to plan, conduct, prepare audit reports, and close out audit
findings.
Where training is provided to achieve competency, documented
information shall be retained to demonstrate the trainer’s competency
with the above requirements

AUDIT
2nd., Party Kompetensi Auditor

AUDIT
PRINSIP AUDIT

AUDIT
SIKLUS PDCA – AUDIT

AUDIT
AUTOMOTIVE PROCESS APPROACH
Pre-audit planning
meeting
Meeting with
Mgt. Rep.
Overview of
processes
Overview of key
process records
Agree scope of audit
Understand sequence
of activities
Understand
process performance
Document review
Audit plan
Construct checklist
Conduct audit
Identify improvements
Document & issue
audit report & CARs
Closing meeting
Present findings
Audit follow-up
and close out
CONDUCTING AN EFFECTIVE
‘PROCESS-BASED’ AUDIT

AUDIT

AUDIT
Level 1
Level 2
Level 3

PLANNING
Department
prepare
medium term
plan
Set up the
production
program
plan
capacities
organize
planning
operation
Set up
budget
SALES
Department
Visit
prospective
customers
manage
orders
negotiate
contract
forecast
sales
Understand
requirements
PRODUCTION
Department
Supply
Operator
maintenance
Manufacture
Inspection
SHIPPING
Department
Approve
transporters
Control
delivery
quality
Organize
delivery
Manage stock
input
Negotiate
supplier
contract
GENERAL MANAGEMENT
Methods
Remote
Supporting
Function
Customer
receives
product
Customer
needs
product
Plan to audit interaction with support processesPlan to audit interaction with support processesPlan to audit interaction with support processesPlan to audit interaction with support processes
Design &
Development
Requirement
Definition &
Communicate
Risk -
Determine &
Communicate
Configuration
Control
V & V
Approach
Producibility
CONDUCTING AN EFFECTIVE ‘PROCESS-BASED’ AUDIT

AUDIT
HASIL PROSES MENCEGAH RESIKO
CustomerCustomerCustomerCustomer
Market Analysis /
OrganizationOrganizationOrganizationOrganization
CustomerCustomerCustomerCustomer CustomerCustomerCustomerCustomer
CustomerCustomerCustomerCustomer CustomerCustomerCustomerCustomer
Bid / Tender
Contract review
Product and
Process Design
Product and Process
Verification & Validation
Production
planning
Delivery
Payment
Warranty / Service
Post Sales /
Customer
Feedback
CustomerCustomerCustomerCustomerCustomerCustomerCustomerCustomer
I O
I
I
I
I
I
I
I
I
I
O
O
O
O
O
O
O
O
O
RISK!RISK!RISK!RISK!
RISK!RISK!RISK!RISK!RISK!RISK!RISK!RISK!
RISK!RISK!RISK!RISK!

AUDIT
TIPIKAL ALIRAN PROSES AUDIT

AUDIT
MENGGUNAKAN TURTLE DIAGRAM

AUDIT
MENGGUNAKAN TURTLE DIAGRAM
Controls
- how?
Inputs ? Process Outputs?
Resources
-with what?
Analysis
– what results?
Support process
- how?

AUDIT
Bagaimana melakukan audit CSR ?
• Audit CSR – bukan melalui referensi yang diterima – tetapi
menjadi satu kesatuan dengan audit proses
• Contoh CSR yang digunakan dalam audit – harus diprioritas
untuk hal yang penting dan/atau berdasarkan isu internal
maupun eksternal – seperti ada kasus/Keluhan pelanggan,
terkait dengan internal performance issues dll.
• Evaluasi tidak cukup bersikap “sesuai” atau compliance akan
tetapi melihat kemungkingan faktor resiko lain yang belum
efektif ditangani dan/atau melihat efektifitas dari tindakan
dengan melihat data – gunakan data secara trend – dalam
kurun waktu yang lama

AUDIT
Bagaimana melakukan audit Core Tools ?
• Audit Core Tools – bukan hanya melakukan evaluasi
penggunaan langsung dan/atau pembuatan langsung
• Core tools diaudit sesuai dengan issue yang dievaluasi –
seperti terjadi Keluhan pelanggan – dikaitkan ke core tools ,
kinerja yang buruk dikaitkan ke core tools.
• Catatlah referensi core tools yang digunakan sebagai bukti
mampu telusur dokumen dan Fakta core tools apa yang
digunakan saat audit

AUDIT
TINDAK LANJUT HASIL AUDIT
Action to eliminate the cause of a
detecteddetecteddetecteddetected nonconformity or other
undesirable situation
Corrective Action
Action to eliminate the cause of a
potentialpotentialpotentialpotential nonconformity or other
undesirable potentialpotentialpotentialpotential situation
Preventive Action

AUDIT
HASIL AUDIT

AUDIT
EVALUASI EFEKTIFITAS AUDIT

Thank You
Danang Widoyoko
+62 811196211
danangwid1987@gmail.com
bersamamitramatra@gmail.com

AK H IR - M O D U LE 6
IATF 16949:2016
S ISTEM M AN A JEM EN M U TU IN D U STR I
OTO M OTIF AU TO M OTIV E Q UALITY
M AN AG EM EN T SYSTEM

Mitra matra iatf 16949 honda module 6

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Mitra matra iatf 16949 honda module 6