Automotive Audits: Principles and Practices

Cover
Half Title
Series Page
Title Page
Copyright Page
Dedication
Table of Contents
Preface
List of Figures
List of Tables
Acknowledgments
Author
Introduction
Chapter 1 Legitimate Concerns about Audits
Chapter 2 Preassessment Preparation
	A Typical Internal Preassessment Survey
Chapter 3 Risk Consideration in Audits
	Risk
		Risk Identification
		Risk Analysis
		Risk Evaluation
		Risk Control
		Risk Communication
		Risk Review
	Methods and Tools Used in Risk Management
		Basic Risk Management Facilitation Methods
		Failure Mode Effects Analysis (FMEA)
		Failure Mode, Effects, and Criticality Analysis (FMECA)
		Fault Tree Analysis (FTA)
		Hazard Analysis and Critical Control Points (HACCP)
		Hazard Operability Analysis (HAZOP)
		Preliminary Hazard Analysis (PHA)
	Risk Ranking and Filtering
	Supporting Statistical Tools
Chapter 4 Audits
	Overview
	Assessment Methods
	Who Is Involved in an Audit?
		Auditor
		Lead Auditors
		Client and Auditee
		Registrar
	Types of Audits
		Internal Audits (Self-Audits)
		Second-Party Audits (Customer Audits the Supplier)
		Third-Party Assessment (A Third Party Audits the Organization’s QMS)
	Audit Planning
	Audit Criteria
	Audit Findings
	Audit Schedule
	Process for Developing Compliance
		Starting
		Documenting
		Evaluating
		Audit Process
			Phase 1 – Preparation
			Phase 2 – Performance
			Phase 3 – Reporting
			Phase 4 – Closure
	Surveillance
	Common Problems in Conducting Audits
	A Guide to the Guide
	Communications
	Cost of Quality and Liability
	Internal versus External Auditors
	Certification versus Noncertification of Auditors
	Ethics
	Recommendations for Improving Ethical Practices
	Conformance versus Compliance
	Verification versus Validation
	The Role of the Consultant in the Documentation and Preassessment Stages
Chapter 5 Mandatory Auditing Items
	An Overview of the Mandatory Documents and Records Required by ISO 9001:2015
		Non-mandatory Documents
	The Detailed Mandatory Documents Required by ISO 9001:2015 Are
	A Guide to the Non-mandatory Documentation
	The Detailed Mandatory Documents Required by ISO 14001:2015 Are
		Non-mandatory Documents
	The Detailed Mandatory Documents Required by OH&S 18001 Are
		Mandatory Records
	Additional Documentation
	The Detailed Mandatory Documents Required by ISO 45001:2015 Are
		Mandatory Records
		Non-mandatory Documents (Procedures)
	The Detailed Mandatory Documents and Records Required by IATF 16949: 2016 Are
Chapter 6 Acronyms
Chapter 7 Methodologies/Tools That the Auditor Should Be Familiar With
	Value Stream Mapping (VSM)
		What You Need to Get Started
		Value Stream Mapping Symbols
		Seven Steps to Value Stream Mapping
		Conclusion
	Operational Excellence versus Continuous Improvement
		Operational Excellence – Some Basic Principles
		Common and Powerful Operational Excellence Methodologies
			Lean Manufacturing
		Six Sigma
		SIPOC Model
		Kaizen
		Achieving Operational Excellence (AOE)
		Steps in Optimizing Business Process Reengineering (BPR)
			Define and Plan the Program
			Designing and Developing the Product
			Aligning Manufacturing Processes for Customer Satisfaction
			Finally, It’s Time for Product and Process Validation
		Assessment and Corrective Action
			Prevention and Diffusion
	PEST and SWOT Analysis
	Turtle Diagram
	Visual Factory
	5S Methodology
	Variety of Applications
	Mistake Proofing
	Role of the Auditor in the Mentioned Methodologies
Chapter 8 Performance beyond Specifications
	Audit Roles
Chapter 9 Quick View of Auditing
	Supplier Quality – Beyond the Minimum Requirements
	Performance to and Beyond Specification Requirements – Quality
	Delivery Performance Including Support of Small Lot Manufacturing – Delivery
	Capability to Continually Reduce Costs throughout the Supply Chain – Cost
	Ability to Respond Rapidly to New Demands, Products, and Issues – Responsiveness
	Supply Chain Principles
	Supply Chain Strategy
	Core QMS Requirements Are Captured In
	Avoiding the Most Common Problems in Supplier Sourcing
	Supplier Development and Improvement
	Complaint Handling
	A Typical QMS Audit
	Requirements Pass-Down
	Penalties and Debits
	Integrated Launch Planning
	FMEA Training and Consulting
	Supplier Certification
		Joint Problem-Solving
		Value Chain Mapping
		Value Analysis (VA)
		Supplier Certification Programs
		Approved Supplier
		Certified Supplier
		Criteria for Qualified Supplier
		Criteria for Preferred Supplier
		Candidates for Supplier Certification and Preferred Status
		Make Allowances for New Materials and Parts
		Certification Maintenance
		Decertification Process
Chapter 10 Process Approach to Auditing
	Process Audit
	What Is a Process Audit?
	Auditing by Element
	Auditing by Process
	Layered Process Audits (LPAs)
		Challenges of Layered Process Audit Implementation
	Error Proofing Audits
		What Is an Error?
		What Does the Standard Require?
		How Do We Error Proof?
	Corrective Action Audits
	Distance Audit
	Internal System Audit
Epilogue
References