TS 16949: 2004 STANDARD FOR AUTOMOBILE & AUTO ANCILLIARY INDUSTRIES

Automobile is the first man-made complex gadget that revolutionized the human civilization and accelerated the pace of economic growth worldwide. In all its complexities, it was a challenge for the human race to make this gadget, almost close to zero defects, though it is produced in millions. It is reported that TOYOTA produced their CORROLA car at 1.96 defects per million cars produced in North America last year. It is believed that 85% of the parts that makes a Toyota car are procured by outside vendors. In the last decade, India has witnessed an explosive invasion of world class automobile manufacturers demanding very high quality standards.

Such a high levels of defect-free output cannot be achieved unless quality management systems are more matured than being involved in mere inspection which detects a wrong product going to the customer. After all, inspection only adds to cost and not to the process improvements. Over the last 5 decades, all automobile giants from US were attempting to develop a comprehensive system that will prevent defects at the source rather than adopting the ineffective quality control methods based on mere inspection.

This effort was commenced when Ford developed a Q101 vendor quality assessment programme in early 80s for their vendors which matured as QS 9000 standard when Chrysler, Ford and General Motors jointly developed this standard. ISO 9000-2000 version brought a new dimension to the management system model in the form of process focused PDCA system. This has resulted in the birth of TS 16949 Sandard in 2002 which has combined all the clauses of ISO 9001-2000 along with the QS 9000 requirements.

Unlike ISO 9000 standard which is very generic in nature, TS 16949 standard is very specific to the auto and auto-ancillary requirements. It has powerful additional process requirements such as Advance Product Quality Planning (APQP), Failure Mode Effects Analysis (FMEA), Design of Experiment, Control Plan, Measurement System Analysis (MSA), Statistical Process Control (SPC) and Production Part Approval Process (PPAP) which helps to build in many bullet-proof prevention systems in the early stages of the product and process development. In addition to the advantage on cost and quality, TS 16949 provides a visa for getting an entry into any automobile industries.


CONSULTANCY DELIVERABLES:

ISO/TS 16949:2002 Certification

The following are the consultancy deliverables for implementation of ISO/TS 16949:2002 Quality Management System.

	Gap Analysis with reference to ISO/TS 16949:2002 standard
	Trainings on the following: - ISO/TS 16949 Awareness Training - ISO/TS 16949 Intensive Training - APQP and Control Plan Training - FMEA Training - MSA Training - SPC and PPAP Training
	Review of critical processes and identifying their interaction throughout the product realization value chain.
	Setting of Process Performance measures & tracking mechanism for all critical processes.
	Implementation of Core Tools: Implementation of APQP (Advanced Product Quality Planning), PPAP (Production and Part Approval Process), Control Plan, MSA (Measure System Analysis), FMEA (Failure Modes and Effect Analysis) and SPC (Statistical Process Control).
	Preparation of Apex Quality Manual and implementation of 7 mandatory documented procedures.
	Conduct internal audits to ensure compliance to all requirement of the international standard before final certification audit.

	Management commitment & involvement
	Regular reviews by the Steering committee
	Careful selection of Project leaders and members
	Attendance to the training programs
	Removal of the road blocks highlighted in the Issue logs & weekly reports of SSA.

The consultants and client are the two interdependent parties and have to execute the projects in a coordinated manner during these times.

ISO/ TS 16949 AWARENESS TRAINING & INTERNAL AUDITOR'S TRAINING:

Apart from setting up a system for ISO/ TS 16949: 2002 Certification, SSA also conducts 1 Day session on Executive Overview/ Awareness on ISO/ TS 16949: 2002; and 2 Days session on Internal Auditor's Training.

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