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QUALITY STANDARDS UPDATE

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QUALITY STANDARDS UPDATE

Mrs. Cherie Reiche Mr. Fred Czubak

International Automotive Oversight Bureau (IAOB)

Fiat Chrysler Automobiles (FCA US LLC)

[email protected] [email protected]

+1 248-358-9793 +1 248-576-6637

Speakers

IATF Structure

• The IATF (International Automotive Task Force) is the recognizing body for ISO/TS 16949 accreditation worldwide – Global Oversight is accountable to the IATF

– Currently, 44 Certification Bodies contract with the 5 IATF Global Oversight Offices

– Global Oversight monitors Certification Body activities (witness audits conducted and maintenance of auditor credentials)

• Listing of the IATF-recognized CBs is available at: http://www.iatfglobaloversight.org/certBodies.aspx

• Only certificates issued by an IATF-recognized CB are valid ISO/TS 16949 certificates

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

IATF Scheme Management Structure

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

Global Certificate Distribution by Region

0.8%

65.5%

18.4% 2.7%

10.0%

2.5%

Africa AsiaPacific

Europe MiddleEast

NorthAmerica

SouthAmerica

Valid Certificates per Region [%]

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

ASIA PACIFIC

41,199 sites

65.45% of worldwide total

CHINA (#1/40%) 25,498

REPUBLIC OF KOREA (#2) 5,089

INDIA (#3) 4,992

JAPAN 1,482

THAILAND 1,468

TAIWAN/ROC 1,323

MALAYSIA 529

AFRICA

505 sites

0.8% of

worldwide total

SOUTH AND

CENTRAL AMERICA

1,595 sites

2.53% of worldwide total

BRAZIL 1,229

NORTH AMERICA

6,322 sites

10.04% of worldwide total

USA (#4) 4,345

MEXICO 1,441

CANADA 530

EUROPE

11,590 sites 18.41% of worldwide total

GERMANY (#5) 3,473

ITALY 1,345

FRANCE 1,012

SPAIN 952

CZECH REPUBLIC 737

UNITED KINGDOM 629

POLAND 621

(only countries listed with more than 500 ISO/TS16949 certified sites)

December 2015 data

MIDDLE

EAST

1,726 sites

2.74% of

worldwide total

TURKEY 906

IRAN 769

Distribution of the 62,942 ISO/TS 16949 certified sites

Since 12/31/2008:

• 59% Global Growth

• 105% Growth in Asia Pacific

© 2016 - International Automotive Oversight Bureau Confidential – Please

do not distribute or copy any of the materials without written permission

Oversight CBs & Certificates

Oversight Office

Certification Bodies

Certificate Count

Percent of Total

ANFIA (Italy)

2 1,751 2.8%

IAOB (USA)

20 20,345 32.3%

IATF France (France)

3 1,999 3.2%

SMMT (England)

6 12,259 19.5%

VDA QMC (Germany)

13 26,588 42.2%

Total 44 62,942 100%

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

IATF Strategies & Concerns

Continue strengthening the value and credibility of TS 16949 certification

– Improve alignment between supplier performance and TS certification

– Emphasize Performance Feedback from Customers (OEMs and Upper Tier Suppliers) during audits, veto power reviews, and certificate decisions

– During CB Office Assessments, the IATF is:

• Looking for evidence of soft auditing (pattern of little to no nonconformities issued) and soft scoring (pattern of issuing minors and no majors) over time

• Watching for differences in the number and type of nonconformities between non-witnessed and witnessed audits

– Certificate decisions must ultimately be based on merit, not “everyone gets one”

• If performance is weak or lacking, the organization can lose their certification

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

Value & Credibility

• IATF OEMs and Global Oversight members look at the linkage between ISO/TS 16949 Certification and Supplier/Client

quality performance

– Increased focus on operational performance and customer feedback (customer scorecards/metrics)

– The IATF is giving support to Certification Bodies to make the right decisions (the “tough calls”)

• Major vs. minor non-conformity

• Certificate suspension or withdrawal

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

Value & Credibility

• OEMs are raising the bar regarding expectations for audits to reflect systemic weaknesses that affect supplier/client performance

• OEMs support increased observation audits and special audits where there is a perceived mismatch between supplier performance and supplier certification status (or increased risk)

Goal = Prevent problems before they occur

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

Value & Credibility

• The Automotive Supply Base has changed dramatically – Suppliers have responded to global competition and significant

economic challenges

– The global footprint reflects the dynamic changes

– TS certificate growth has been largely in Asia Pacific

• In response, Key Stakeholders expect more from TS 16949 – Compliance to the standard is a requirement – It has become the price

of entry

– Expectations are that poor performing suppliers should not be TS Certified

So let’s take a look at our areas of weakness ….

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

Top 10 Nonconformities (by ISO/TS clause – global)

Corrective Action

Monitoring/Meas

Internal Audit

Cntrl Prod/Servicing

Monit/Meas Equip

Control Plan

Mfg Proc Design

Meas Sys Analys

Mon/Meas Mfg

Prev/Predict Main

Cntrl Prod/Servicing

Control Plan

Prev/Predict Main

Mfg Proc Design

Monit/Meas Equip

Special Charact

Corrective Action

Monitoring/Meas

Work Instructions

Meas Sys Analys

Nonconformities in BLUE appear in both Top 10 lists

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

IATF Strategies & Concerns

• Revise TS 16949 based on ISO 9001:2015 structure and boxed text

• Develop common audit report template including follow-up audits and upload into the IATF database

• Continue focus on rapidly growing TS certification in Asia Pacific, primarily China

• Utilize OEM Directed Witness Audits to enhance supplier performance, new processes, new supplier, and launch readiness

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

ISO/TS 16949 Revision Process

• IATF launched a survey (via the National Associations) early June 2015 soliciting feedback from over 2,000 key stakeholders: – OEMs

– Suppliers (all Tiers)

– Certification Bodies

– Witness Auditors

– Subject Matter Experts

– Oversight Offices

• Over 1,700 comments were received for consideration of updates to ISO/TS 16949

• Timing for release of draft materials to be determined

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

PAGE 15

Survey respondents

63%

17%

9%

8% 2% 1%

Suppliers

Certification Bodies

OEM

Witness Auditors

Oversight Offices

Subject Matter Experts

ISO/TS 16949 Revision Process

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

PAGE 16

8.5%

3.6% 5.4%

9.4% 9.4% 12.1%

49.3%

0%

10%

20%

30%

40%

50%

60%

1 2 3 4 5 6 7

Prioritization 1 = lowest / 7 = highest

Harmonization of CSR & Inclusion in the standard

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

PAGE 17

Harmonization of Core Tools

6.0% 5.0% 6.9%

16.1% 16.1%

21.1%

27.5%

0%

10%

20%

30%

40%

50%

60%

1 2 3 4 5 6 7

Prioritization 1 = lowest / 7 = highest

Harmonization of Core Tools

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

PAGE 18

Prioritization 1 = lowest / 7 = highest

12.1%

7.6% 9.4%

16.1%

11.2%

19.6%

23.7%

0%

10%

20%

30%

40%

50%

60%

1 2 3 4 5 6 7

Harmonization of internal audit

process methodologies

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

PAGE 19

Prioritization 1 = lowest / 7 = highest

12.4% 12.8%

8.3%

15.1% 12.4%

17.4% 18.3%

0%

10%

20%

30%

40%

50%

60%

1 2 3 4 5 6 7

Specific requirements for

sub-tier suppliers

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

PAGE 20

Prioritization 1 = lowest / 7 = highest

11.3% 8.0%

9.9% 10.8%

20.8%

17.0% 20.3%

0%

10%

20%

30%

40%

50%

60%

1 2 3 4 5 6 7

Improve correlation between audit results

and lack of performance

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

PAGE 21

Prioritization 1 = lowest / 7 = highest

4.7%

8.4% 9.8% 12.6%

19.1%

15.3%

26.0%

0%

10%

20%

30%

40%

50%

60%

1 2 3 4 5 6 7

Improvement of IATF Rules

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

http://www.iatfglobaloversight.org/content.aspx?page=IATF ISO/TS 16949 Revision Workgroup News

Please stay tuned to the IATF Global Oversight

website for updates

© 2016 - International Automotive Oversight Bureau Confidential – Please do not distribute or copy any of the materials without written permission

Problem prevention

• Stay focused on value and credibility of ISO/TS 16949

• ISO/TS 16949 revision process on-going – stay tuned to the Global Oversight website for updates

• Rapid growth of the automotive supply base in the Asia Pacific region is of key importance to the IATF

– Asia Pacific region Deep Dive Audits

– Increased Witness Audits

• Further strengthen the performance linkage among OEMs, Suppliers (all tiers), CBs, and Oversight Offices

Focus the Supply Base on more opportunities for systemic problem solving – preventing problems upfront.

© 2016 - International Automotive Oversight Bureau Confidential – Please do

not distribute or copy any of the materials without written permission

While I have your undivided attention…

Let’s talk about Warranty!

Confidential Information – ©2016 FCA US LLC

Why worry about Warranty?

Warranty reduction benefits both FCA US LLC and suppliers

• Provides short and long-term financial benefits – Reduces FCA US expense

– Minimizes supplier exposure

– Improves customer perceptions

• Accelerates continuous improvement (PDSA)

• Develops a more positive FCA US / supplier relationship

Confidential Information – ©2016 FCA US LLC

Why worry about Warranty?

Confidential Information – ©2016 FCA US LLC

It appears in ISO/TS 16949 and FCA US Customer-Specific Requirements

Why worry about Warranty?

It’s also a contractual requirement

8. GENERAL WARRANTY.

any warranties implied by law or otherwise made by Seller shall be determined in accordance with the Supplier Associated Warranty Reduction Program Policies and Procedures or any successor program or policies as published on the FCA US Supplier Portal

Confidential Information – ©2016 FCA US LLC

20%

20%

20%

20%

20%

Quality Delivery

Partnership

Cost Warranty

• 20% of the overall supplier score

• Aligned with the Supplier Associated Warranty Reduction Program (SAWRP)

Why worry about Warranty?

And it’s a performance metric

Confidential Information – ©2016 FCA US LLC

• Familiarize your company with the Supplier Associated Warranty Reduction Program (SAWRP)

• Implement a CQI-14 compliant warranty management process

• Review warranty data available from FCA US Warranty systems

• Visit the Parts Return Center regularly, obtain returned parts for analysis and respond to requests from QEC Warranty Specialists

Why worry about Warranty?

Confidential Information – ©2016 FCA US LLC

What’s expected of suppliers?

What is CQI-14?

• A guideline of industry best practices in automotive warranty management

• A development of a cross-functional task force (17 suppliers and 5 OEMs)

• The basis of FCA US’s associated warranty management requirements

Why worry about Warranty?

Confidential Information – ©2016 FCA US LLC

• https://www.aiag.org

• Customer service: (248) 358-3003

• International Customer Service: (877) 275-2424

Why worry about Warranty?

Where can I get a copy of CQI-14?

• eSupplierConnect: Supplier Warranty Management home page

• Direct e-mail: [email protected]

Where can I get more information on FCA

warranty requirements?

Confidential Information – ©2016 FCA US LLC

Thank you!