For many organizations implementing the IATF 16949 system, qualifying and maintaining auditor is always a process requiring more resources and time consuming. Compared to the typical ISO9001, IATF specifically require a longer and more in-depth list of competencies as stated in the requirements under 7.3.2 Internal auditor competency, as follows:
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.
This long list of competencies is therefore demanding for companies. Let’s look at this from 3 perspectives.
First perspective: Why?
Automotive industry is a rather technical by nature. After more than 100 years since the first T-model from Ford arrives, the automotive industry has evolved in such a big manner. Today we are seeing more technologies arriving with the convergence of electronics and communication technology in the vehicle.
Unlike other industry, on the automotive shop floor, use of core tools such as APQP, PPAP and FMEA is the norm especially during development of a new product. MSA is required for assessing suitability of measurement system. SPC is used to monitor the stability and capability of production process. Control plan is the heart of all documentation on the shopfloor to state clearly the daily control methods deployed. Lean manufacturing methods such as pull-production, SMED, and line balancing are all every day practice. Not enough, there are countless quality and production tools applied such as 8D, 5Whys, Poka-Yoke, etc. if the auditor does not understand any of these, it would be impossible to audit as it is the primary language for automotive.
Second perspective: Who?
Given the much more demanding list of competency required, we would be asking for trouble if do not give it some thoughts over selection of candidates to be qualified as auditors. The criteria for consideration should be a mix of education, experience and training. In Asia, we generally recommend candidates with at least a diploma or university degree especially when you required auditor report to be written in English. As for work experience, formal IATF auditor qualification used to require 10 years of automotive experience. Recently this has been reduced to 4 years. A four year experience would be good for supplier auditors but internal auditors may make do with a minimum of two years. Any period shorter would require some form of justification.
Third perspective: How?
How many auditors should I train? Well, it really depends on size of your organization. As a reference, for any company with 200 to 500 employees, 20 would make a rationale figure. More than that, you do the math for extrapolation. Remember though that having 10 good auditors is way better than 50 mediocre ones.
The most practical solution is to have a customized route with consideration for work experience and training. The competencies in IATF requirements 7.2.3 (a), (c), (e) may be addressed via classroom training. Competency for core tools in 7.2.3 (d) may be addressed via work experience, e.g. an engineer who is involved in new project would fit the experience for APQP. Alternatively classroom training may fill in the gap. Customer specific requirements in item (b), would best be done via internal briefing. It would be impossible to have a formal CSR training as no tutor is qualified except the customers themselves. A briefing using the CSR matrix in the quality manual supported by latest version of CSR document from customer would be the best solution. As for those who play the role of Team leader or those who primarily audit external suppliers, a lead auditor certificated training would be ideal. The certification would lend credibility for person performing audit representing your organization.
Note: Our IATF-approved Lead Auditor Courses are conducted throughout the year. The 5-day course comes with proctored examination. The certificate is awarded via SMMT, the IATF UK oversight entity. Leo Ardent is the official approved licensed training partner of SMMT.