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Participant Document Automotive Core Tools for Auditors

MLA Group Work

Å VDA QMC Version 11/2019 1

Group Work 1

MLA

You will audit the area of product and (production) process development and talk to the project manager in the company.

The project under consideration is a platform component for the VW Group and is currently about 2 months before SOP. From the audit preparation you know that the company has unconditionally accepted the customer requirements (formula Q) in all parts and accepted them as the contractual basis. The affected component was classified by the customer as having maturity risk C.

You can see how the project is proceeding and see that the project status conforms to the schedule. If you take a closer look at the milestones, you will see that the company works with its own PDP model with a total of 4 phases + one handover to series production.

The project is currently in internal phase 4 and shows the status yellow. A closer look reveals that various tasks (measurement criteria) from Phase 3 (determination of measurement system analyses for process 14 "Final Inspection" & assembly and commissioning of the series machine for process 13 "Final Assembly") had not yet been completed and were rated red at the time of the review. Measures have been defined and scheduled up to 1 week before SOP.

Decide, as a group, what questioning technique you will use and consider appropriate questions for the case study. Make sure that your questions are focused on the "weakness of using the MLA method".

Time limit: 10 minutes

Case Study

Task 1

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MLA Group Work


Group Work 1

Read the following audit interview:

" Do you consider your questions?

" How do you assess the situation in the group?

" Formulate at least 2 potential findings from the audit interview relating to the case study.

Time limit 15 minutes

1st Question: How do the internal 4 phases + transfer phase model correlate with the VDA maturity model?

Answer: We have our own checklist and so far nobody has asked for anything else.

2nd Question: What was the status of the VDA maturity assessments of the previous maturity levels?

Answer:We have our own checklist plan for each phase and do not use an RGA measurement criteria list.

3rd Question: Which criteria are used to carry out the internal traffic light evaluation?

Answer:Green when all tasks are completed! Yellow if task is not completed, but a task is defined! Red if none is defined!

4th Question: What information was provided to the customer after Phase 3 Review (escalation to customers according to maturity risk C)?

Answer: None. We have an internal escalation model and accordingly escalated to the so-called "Steering Committee".

5th Question: Which decision was made by the Steering Committee in the course of the escalation?

Answer: No information to customers, because we want to have the series machine in house until 1 week before SOP.

Audit Interview Situation

Task 2

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FMEA Group Work


Group Work 2

FMEA

Develop process element 6 "Process Analysis/Production" as a group task. Deal with the sub-element assigned to your group.

1. FMEA Step 2 Group




1. Give examples of possible minimum requirements and suitable evidence that can be used to assess the issues in your FMEA step.

2. Define appropriate audit questions to obtain the audit evidence. Hint: open questions

3. Identify potential deviations that match the requirements and questions. Hint: keywords only

4. Present on a single flipchart for plenary discussion.

Time limit: 30 minutes Presentation: 5 minutes per group

Groups

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MSA / Capability of Measurement Systems


Group Work 3

Measuring and Testing Processes

Reading exercise in the standards and assignment of requirements regarding procedures for identification of non-compliance with requirements (product conformity).

1. Read section 7.1.5 Resources for monitoring and measurement in ISO 9001:2015 as well as the corresponding additional requirements of IATF 16949 and the VDA 6.3 requirements in P6.4.3.

2. Identify the requirements set out in the norms/standards and the VDA 6.3 minimum requirements and write them down individually on cards (max. 5 per standard).

Resources:

ISO 9001:2015 VDA 6.3:2016 IATF 16949:2016 Script

Task:

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Group Work 3

DIN EN ISO 9001:2015 7.1 Resources

7.1.5 Monitoring and measuring resources

7.1.5.1 General

The organization shall determine and provide the resources needed to ensure valid and reliable results when monitoring or measuring is used to verify the conformity of products and services to requirements.

The organization shall ensure that the resources provided:

a) Are suitable for the specific type of monitoring and measurement activities being undertaken;

b) are maintained to ensure their continuing fitness for their purpose.

The organization shall retain appropriate documented information as evidence of fitness for purpose of the monitoring and measurement resources.

IATF 16949:2016 7.1 Resources

7.1.5 Monitoring and measuring resources

7.1.5.1.1 Measurement systems analysis

Statistical studies shall be conducted to analyse the variation present in the results of each type of inspection, measurement, and test equipment system identified in the control plan. The analytical methods and acceptance criteria used shall conform to those in reference manuals on measurement systems analysis. Other analytical methods and acceptance criteria may be used if approved by the customer.

Records of customer acceptance of alternative methods shall be retained along with results from alternative measurement systems analysis (see Section 9.1.1.1).

NOTE Prioritization of MSA studies should focus on critical or special product or process characteristics.

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Group Work 3

VDA 6.3:2016 P 6.4 What means are used to implement the process? Material resourcesP6.4.3* Can the quality requirements be effectively monitored with the measurement

and test facilities in use?

Test and measuring equipment/facilities used are suitable for the planned purpose and handling in production. They are included in the control plan.

Capability studies are carried out on the test and measuring equipment/facilities employed. There is an identification system for test and measuring equipment. Administration of this equipment is based on the identification.

A process for the periodic monitoring of measurement and inspection equipment is installed and implemented (responsibility for collection and return is defined). This process also takes into account the calibration of process-integrated measurement technology with an influence on the product characteristics.

Auxiliary equipment for measuring and test equipment that have an influence the measurement result are monitored in the same way.

� Control plan

� Capability of test equipment

� Capability of measuring equipment

� Capability of measurement process

� Data collection and interpretability

� Evidence of the calibration of inspection equipment

� Comparison of inspection equipment/measurement processes with the customer (e.g. inter-laboratory comparisons)

� Inspection stickers or certificates

� Reference component/setup parts (e.g. error test pieces)

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PPA Group Work


Group Work 4

Production Process and Product Release

You are conducting an external audit with one of your engine component suppliers. In detail, the audit deals with exhaust gas recirculation including the legal requirements for compliance with emission limits. The project is already one year after SOP. You are currently looking at the PPA approvals of the subcomponents according to VDA 2. In the case of 2 of 8 components, the overview table shows a conditional approval (yellow / note 3).

Decide, as a group, what questioning technique you will use and consider appropriate questions for the case study. Questions should be focused on "method implementation weaknesses".


Case Study

Task 1

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PPA Group Work


Group Work 4


" How do you assess the situation?

" Formulate at least one potential finding from the audit interview relating to the case study.


1st Question:What is the reason for the conditional release?

Answer:The supplier has not demonstrated the required process capabilities for certain characteristics.

2nd Question:Which characteristics are affected?

Answer:I cannot tell you exactly, the responsible colleague from the project has left the company a long time ago. I've taken over the duties and you know.... The colleague was only there for one day when I started.

3rd Question:What kind of safeguards does the supplier use as an alternative?

Answer:In accordance with the descriptions in the PPA cover sheet, a shorter sampling interval (from 5 every 4h to 5 every 2h) was defined as the requirement until the required process capabilities were presented.

Task 2

Audit interview situation

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PPA Group Work


Group Work 5


You are auditing the supplier management department in your own company. You are currently looking at the PPA releases for assembly. This is a release for a product change that has been carried out. The change was notified and performed in accordance with the trigger matrix.

The documentation in the case file and the PPA cover sheet show Submission Level 0 (no documentation and only the PPA cover sheet is filled in). When viewing the cover sheet, you notice that item 1 of 22 is indicated as conditionally OK (yellow/note 3). The overall decision is OK (green/note 1).

Decide, as a group, what questioning technique you will use and consider appropriate questions for

the case study. Questions should be focused on "method implementation weaknesses".


Case Study

Task 1

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PPA Group Work


Group Work 5





1st Question:How was the sampling planning conducted?

Answer:I don't know exactly, the coordination with the supplier takes place via our purchasing department.

2nd Question:Which submission level was agreed/ordered with the supplier?

Answer:This is a standard supplier. Here no specification was made to the supplier.

3rd Question:What is the reason for the conditional OK rating for position 1?

Answer:There were minor deviations from unimportant measurements.

4th Question Why was the overall decision set to OK (green/note 1)?

Answer:Our construction department believe that the deviations have no influence on the function.

5th QuestionWhat documented information exists on this decision?

Answer:Something like that happens with us through the short official channels.

Task 2

Audit interview situation

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PPA Group Work


Group Work 6


As SQE, you are on site at your supplier for plastic injection molded parts. You are looking at the status of the release of a current technical process change. 4 weeks ago, the change was OK (green/note 1) and approved for delivery.

When reviewing the documentation, the account manager of the audited organization only finds the signed PPA cover sheet for the case.



Case Study

Task 1

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PPA Group Work


Group Work 6





1st Question: Which further proofs were generated in the context of the internal release for the PPA procedure?

Answer: None, we have only carried out a so-called "cover sheet sampling".

2nd Question: What agreements were made in this respect during the sampling planning discussion?

Answer: There was no sample planning discussion. There shall be no further coordination in the case of cover sheet samples.

3rd Question: How was Submission Level 0 agreed?

Answer: There was an e-mail from your department saying that you only expect Submission Level 0. Please look, here's the e-mail! We always store such correspondence.

Task 2


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CmK/PpK/CpK Group Work


Group Work 7

Capabilities

You are shown the PPF documents in the context of an audit after a process change has been carried out. The SOP took place 2 years ago and the change was reported to the customer in advance and "sampled" again for Submission Level 2 by agreement.

When the statistical data was inspected, a Cpk was shown for a characteristic 20.25 /- 0.15 with the result 1.78 capable!

You can see from the document that a total of 30 parts have been inspected.



Case Study

Task 1

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Group Work 7





1st Question: How was the sampling carried out (type and period)?

Answer: 50 parts were removed one after the other from the process.

2nd Question: What are the customer requirements for the threshold values (>1.33 or 1.67)? Answer: It's about a component for different customers.

Customer A demands CmK 1.67 / PpK 1.67 & CpK 1.33

Customer B demands CmK 2.0 / PpK 2.0 & CpK 1.67

Task 2


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Group Work 8

Capabilities

You are auditing a plastic injection molding company in preparation for the SOP in 4 weeks. In the current project status, the PPAP documentation was recently submitted to the customer according to Submission Level 4.

You are shown the corresponding internal documentation. You can see that so far there has only been one Cmk study for defined characteristics in the scope of statistical studies. This was demonstrably agreed with the customer because there had not yet been a sufficiently large production batch.

When you look at the CmK evaluations in detail, you see the following:



Case Study

Task 1

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Group Work 8





1st Question: Where does the Excel template for the evaluation of the Cmk values come from?

Answer: We have stored it as a form in our document control with the form number 12345not normal distribution.

2nd Question: Which other Excel templates are available in the document control for the evaluation of statistical parameters?

Answer: We have there I believe further to the evaluation templates of measuring device capabilities. To simplify things, I copied the template used here to my desktop to have quick access. You can display the other templates in the document control. And you see: 2345not normal distribution / 56789VF1 / 8956VF2 / 43678VF3

3rd Question: How do you know which of the forms listed here is the correct template for the feature in question?

Answer: We distinguish only between measuring equipment capability and process capability and here we are

talking about process capability.

Task 2


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Group Work 9

Record the conversation presented and recognize the connection to the case study.




1st Question: Which planned sample size was used to calculate the action limits?

Answer: I don't understand the question. The action limits are specified by the format of the control chart and are determined by the quality department in accordance with internal instruction 4711.

2nd Question: What does statement 4711 describe?

Answer: The action limits are calculated according to the assumption of a probability of error of alpha 1% (not Anglo-Saxon) and n=5 is planned by default. The corresponding QRK template is specified as a valid document FO 0815 in the instruction.If you look at the calculation formula, you will see that the quantiles for EGo 0.484 and EGu 17.8 are used for the standard deviation chart.

When viewing the calculation formula for the EC of the mean value chart, you can see that the quantile 3.00 is inserted.

3rd Question: Why are only n=3 listed in the control chart and PLP?

Answer: As part of an optimization process by the OPEX team, it was determined that there would be no significant differences in the results, even with n=3. This made it possible to save 2 measurements, which significantly streamlines the process.

4th Question: When were the action limits recalculated?

Answer: This was not necessary because we have had good experience with the defined action limits.

Task 2


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Group Work 8D


Group Work 10

8D Problem Solution

You are auditing one of your suppliers on behalf of the purchasing department. The matter involves high quantities of stamped parts which the supplier buys in and then only cleans and forwards to you. These parts are then plastic-coated in your company. You are currently auditing the problem-solving process at the supplier. From the preparation for your audit assignment, you know that in the recent past there have been repeated internal deviations to overfeeding in the peripheral areas of your parts.

Approximately 8 months ago, a complaint (No. 0815) was made with the audited supplier regarding burr formation. According to your system information, this complaint was closed by the responsible supplier liaison and was rated with 10 of 10 points in the internal 8D Assessment. A direct connection between the burr formation and the overfeeding was confirmed in your company. Two days ago, a new complaint was lodged due to burr formation.

A response up to D3 is not yet available, but is expected by the deadline of day 3. The deliveries are currently not at risk. You have the 8D report on the process from 8 months ago shown to you and you can see that there has been a technical and systematic measure taken by the subcontractor, which has been verified and is effective. Among other things, the inspection process has been optimized and a shorter maintenance interval for cutting tools has been introduced. These measures became effective for the first time on May 18. You were also shown the corresponding 8D report from the subcontractor, which was conclusive and plausible.

Further discussion in the plenary.



Task 1

Case Study

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Group Work 8D


Group Work 10

Record the conversation presented and recognize the connection to the case study.


" Formulate at least 1 potential finding from the audit interview relating to the case study.


1st Question: What information has already been transmitted to you by the subcontractor for the new process (8D Report)?

Answer: A complete 8D Report has already been sent. The supplier has completely rejected the process.

2nd Question: What are the reasons for this?

Answer: We can have a look together! With the current daily workload, I do not have all the details in my head.

You look at the 8D Report and find the following text in D4:

The parts complained about from delivery note no. 4711 originate from a production batch dated March 16 and thus before the introduction of the optimization measures triggered by the initial complaint.

Based on this fact, no measures are described below in D5, D6 and D7.

Reference is made to the effective measures of the first 8D Report.

Task 2


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