auditor

ISO 9001:2015 June Webinar

Quality Professionals are invited to attend an open forum on expected changes to the ISO 9001:2015 International Standard. This forum is part of a series of updates from Charleston area subject-matter experts aimed at assisting organizations in their preparation of the upgrade to the new standard. The panel of experts will include veterans from various sectors such as automotive, aerospace, environmental and information security to discuss the potential impacts on various industry-specific standards (ISO/TS 16949, AS9100, ISO 27001 and ISO 14001).

3 SEATS LEFT for ISO/TS 16949:2009 Internal Lead Auditor (32hrs)

Folly Beach - Charleston BeachesLast call for our Fall 2014 Automotive Quality Series with our ISO/TS 16949:2009 Lead Internal Auditor Course. We have THREE seats remaining. The courses will be held at the aLoft Charleston Airport & Convention Center. Learn by day. Hit the beach after class. Why not make the most of your professional development? Don't just take a class - experience business differently. Price includes all course materials, parking, wifi, light breakfast, lunch & afternoon snacks. Dozens of food and entertainment options are within blocks from the hotel.

Register & pay online here or by calling 843.469.8279.

Description:   This advanced internal auditing course caters to the full spectrum of auditor responsibilities – from process auditing to audit program management. This course will teach you the fundamental tools necessary to conduct audits using the automotive process approach while providing vital strategic information to top management. Case studies and scenarios make this course fun. If you are looking for a Lead Auditor course for internal processes or supplier quality development, look no further. This course is for you. NEW: We will also discuss the TS Rules 4th Edition and draft of the proposed ISO 9001:2015 standard. Get a jump on what to expect with the changes and it’s potential effect on your management system implementation.

Designed for:  Audit Program Managers, Lead Auditors, Advanced Audit Team Members, Supplier Quality Engineers & Managers, Process Improvement Managers, Quality Directors, Continuous Improvement Managers, Organizational Development Directors, Management Representatives

This course meets or exceeds the training requirements for:

  • Ford Customer-specific Internal Quality Auditor requirements
  • General Motors Customer-specific Internal Quality Auditor requirements

Length:  4 days/32 hours   CEUs:  3.2    A certificate will be given upon successful completion of all course requirements.

The instructor for this course will be Jim Thompson, President of Concentric and Exemplar Global (formerly RABQSA) Accredited QMS Lead Auditor. Register online here, contact us by email at info@cmsicharleston.com or by calling 843.469.8279.

Day 1
▪    Introduction & Welcome
▪    Gathering of Student Goals & Expectations (CSRs)
▪    Overview of ISO 9001 & ISO/TS 16949 – Part I
▪    Selling QMS to Top Management
▪    The Automotive Process Approach
▪    Overview of ISO 9001 & ISO/TS 16949 – Part II
 
Day 2
▪    Use of Turtle Diagrams for Process Mapping
▪    ISO/TS 16949 Requirements – Clause 4.0, Quality Management System
▪    ISO/TS 16949 Requirements – Clause 5.0, Management Responsibility
▪    ISO/TS 16949 Requirements – Clause 6.0, Resource Management
▪    Overview of AIAG Core Tools (APQP & CP, FMEA, MSA, PPAP & SPC)
▪    ISO/TS 16949 Requirements – Clause 7.0, Product Realization
 
Day 3
▪    ISO/TS 16949 Requirements – Clause 7.0, Product Realization
▪    ISO/TS 16949 Requirements – Clause 8.0, Measurement, Analysis & Improvement
▪    Audit Objectives & Auditor Attributes
▪    Process Auditing Breakout
▪    Writing Audit Findings – NCRs & OFIs
 
Day 4
▪    Reporting Audit Findings
▪    CAPA – Corrective Action & Preventive Action
▪    Closing Out Audit Findings
▪    Closing the Audit Cycle
▪    Evaluating Audit Effectiveness
▪    Final Review/Q&A
▪   Student Goals & Expectations (Reviewed)
▪   Course Examination
 
 

Writing a Nonconformance (NCR)

NCR can find broken processes and really help with profit improvement "A problem well stated is a problem half solved." - Charles F. Kettering, American Inventor & Social Philosopher

The first step in solving a problem is to ensure you fully understand what the problem actually is. I regularly see horrible examples of this in practice inside some of the companies I work with. One classic example was in Atlanta, GA a few years ago. Here is the scenario...

Operations Manager: "What the h@!! is going on? Logistics has dropped the ball again! Our #1 line is down because they can't get their heads out of their a$$e$ and keep up with ordering the resin we need. This is our biggest customer!"

The scenario, at least in the mind of the Operations Manager, was that the Jack-Wagons working over in the Logistics Department simply couldn't count. I didn't buy it. In this case, as in most cases where suppositions seem a bit unlikely, I decided to do something I typically do during an audit - walk the audit trail by following the process upstream. This seems like such an obvious move... 1. There's a problem. 2. Walk the trail to find out the source. 3. Ask questions and "show me, show me, show me". HOWEVER, in many organizations, the minute an employee crosses the line into another department he/she is outside of their home turf. A defensive culture will likely breed a departmental approach (staying in your own neighborhood) versus a process approach. If you are not familiar with the process approach, you can learn more about this methodology here from a March 2011 post.

After walking the trail and crossing the territorial boundaries of Production into Scheduling and on to Logistics, I was able to trace back the material in the ERP system with the status "On Hand" and location "Op 120" -  which was the Molding Operations where I had started my hunt. After circling back around to the Operations Manager and hearing another string of Logistics bashing, I started to do some real snooping in the surrounding areas.

Standing at what I'd like to call the base camp of "Mount Unknown Product", I rolled up my sleeves like a eager bidder on Storage Wars and sifted through stacks of components, raw materials and residual miscellaneous. No luck there, although I noted the lack of control and visited that area later in the audit. After asking several questions of several Molding Operators, one of the ladies jumped in with "Oh yeah, that's probably that skid over there in the corner." Sure enough, the skid we were looking for was off in the corner with a simple 2"x2" yellow sticky label on it marked "BAD PRODUCT".

After pointing out to the Operations Manager that the source of the problem was likely one of his team members as opposed to those fools in Logistics, I asked him to consider a better solution. I then pointed out how I would be writing a Nonconformance Report for this finding, and how my nonconformance statement would clearly define the problem at hand. I jokingly stated, "If you want, I can write this NCR in a similar way as that sticky note? I can simply write 'Bad Process' and let you try to remember what I actually meant." He didn't think it was funny.

There were several missing links to the materials and inventory control process I observed during this audit; none that included someone coming to work deliberately trying to screw things up. Links that were obviously broken were the identification of product, controlling suspect or known nonconforming product, use of approved documentation and recording the instance of a nonconformity. An important transactional control was also missing, which was the signal used to notify Logistics that the parts were now unavailable. That signal should have been an ERP move from "Op 120" to "Op 120 Hold". That move to Op 120 Hold would have signaled the Logistics group to order another batch of components in order to keep the customer's order moving forward.

At the end of the day, the use of a simple 1-page Nonconformance Report (NCR) that forces the Originator to follow a simple process checklist (i.e. Yes/No - Did you move product out of IN PROCESS into a PRODUCT HOLD Operations?) may have prevented a late shipment. By the way, the company's poorest performing KPI (key process indicator) was "% On Time Delivery". This KPI was also tied to their variable compensation profit sharing process.

Nonconformance Report (NCR)

Here is an example of a simple NCR Form that may be useful in improving YOUR bonus payout. Click on the image to launch the product and view the PDF or download the native version. Who would have thought a simple form could make your customer and your wallet happier?

Cheers,

Jim Blog Signature

TSLA August 2013

TWO Sessions August 27-30, 2013  |  Columbus, IN & Charleston, SC

ISO/TS 16949:2009 Internal Lead Auditor Training (32hrs):  $1495*

SummerSpecialThe courses will be held at the new Harbor Breeze on Patriots Point in beautiful Mt. Pleasant, SC (Charleston). Students attending our Indiana course will be catered to by our great friends - who always receive outstanding hospitality reviews - at Tre Bicchieri in downtown Columbus.

Register online here or by calling 843.469.8279.

Description:   This advanced internal auditing course caters to the full spectrum of auditor responsibilities – from process auditing to audit program management. This course will teach you the fundamental tools necessary to conduct audits using the automotive process approach while providing vital strategic information to top management. Case studies and scenarios make this course fun. If you are looking for a Lead Auditor course for internal processes or supplier quality development, look no further. This course is for you. NEW: We will also discuss the CD1 draft of the proposal ISO 9001:2015 standard and it's potential effects on your management system implementation.

Designed for:  Audit Program Managers, Lead Auditors, Advanced Audit Team Members, Supplier Quality Engineers & Managers, Process Improvement Managers, Quality Directors, Continuous Improvement Managers, Organizational Development Directors, Management Representatives

This course meets or exceeds the training requirements for:

  • Ford Customer-specific Internal Quality Auditor requirements
  • General Motors Customer-specific Internal Quality Auditor requirements

Length:  4 days/32 hours   CEUs:  3.2    A certificate will be given upon successful completion of all course requirements.

*Price include training materials and training facilities for each student.  SEND TWO STUDENTS & THE THIRD STUDENT ADMISSION IS FREE!  Promo Codes: 2for3 for multi-student early registration

All of our instructors are accredited with extensive industry expertise in the respective course(s) they teach.  CVs/Resumes can be provided upon request at any time. Register online here, contact us by email at info@cmsicharleston.com or by calling 843.469.8279.

Day 1
▪    Introduction & Welcome
▪    Gathering of Student Goals & Expectations (CSRs)
▪    Overview of ISO 9001 & ISO/TS 16949 – Part I
▪    Selling QMS to Top Management
▪    The Automotive Process Approach
▪    Overview of ISO 9001 & ISO/TS 16949 – Part II
 
Day 2
▪    Use of Turtle Diagrams for Process Mapping
▪    ISO/TS 16949 Requirements – Clause 4.0, Quality Management System
▪    ISO/TS 16949 Requirements – Clause 5.0, Management Responsibility
▪    ISO/TS 16949 Requirements – Clause 6.0, Resource Management
▪    Overview of AIAG Core Tools (APQP & CP, FMEA, MSA, PPAP & SPC)
▪    ISO/TS 16949 Requirements – Clause 7.0, Product Realization
 
Day 3
▪    ISO/TS 16949 Requirements – Clause 7.0, Product Realization
▪    ISO/TS 16949 Requirements – Clause 8.0, Measurement, Analysis & Improvement
▪    Audit Objectives & Auditor Attributes
▪    Process Auditing Breakout
▪    Writing Audit Findings – NCRs & OFIs
 
Day 4
▪    Reporting Audit Findings
▪    CAPA – Corrective Action & Preventive Action
▪    Closing Out Audit Findings
▪    Closing the Audit Cycle
▪    Evaluating Audit Effectiveness
▪    Final Review/Q&A
▪   Student Goals & Expectations (Reviewed)
▪   Course Examination
 

October Course Quickly Approaching

LAST CALL FOR OCTOBER 2011 COURSE

ISO/TS 16949:2009 Internal Lead Auditor Training (32hrs)  |  October 24-27, 2011 - Charleston, SC

Additional course dates:

November 14-17, 2011 - Columbus, IN December 12-15, 2011 - Charleston, SC 

Course Description

Join us at The Tides - Folly Beach, SC.  Bring your family or friends so you can join them for fun in the sun in between classes!  Group rates starting at only $129/night with advanced registration.

This advanced course caters to the full spectrum of ISO 9001 and ISO/TS 16949 auditor responsibilities – from auditing using the most effective automotive process approach to audit program management.  If you are looking for a Lead Auditor course for internal processes or supplier quality development with a focus on the automotive process auditing and use of the AIAG core tools, look no further. This course is for you!

This course will teach you the fundamental tools necessary to conduct audits and provide vital strategic information for SELLING your findings to top management in order to improve organizational objectives. You will also learn the requirements associated with properly addressing nonconformities to prevent recurrence and pro-active techniques for evaluating business risks. Real world tools, case studies and scenarios make this course a challenge, but a lot of fun.

This course meets or exceeds the training requirements for:

  • Ford Customer-specific Internal Quality Auditor requirements
  • General Motors Customer-specific Internal Quality Auditor requirements

Length: 4 days/32 hours CEUs: 3.2 A certificate will be given upon successful completion of all course requirements.

ISO/TS 16949:2009 Internal Lead Auditor Training (32hrs): $1495*

*Price include training materials and training facilities for each student.  SEND TWO STUDENTS & THE THIRD STUDENT ADMISSION IS FREE with our 30-day Pre-Pay Option!   To register, reach us by email at jim.thompson@cmsicharleston.com or by calling 843.469.8279.

All of our instructors are accredited with extensive industry expertise in the respective course(s) they teach. CVs/Resumes can be provided upon request at any time. To register, complete our Course Registration Form, contact us by email at jim.thompson@cmsicharleston.com or by calling 843.469.8279.

Course Agenda

DAY ONE

Title

Start

Finish

Chapter 1 - Course Introduction

8:00

8:30

Interview Exercise

8:30

9:15

Chapter 1.5 – Introduction to ISO / TS 16949 including CSRs

9:15

10:00

Break

10:00

10:15

Team Exercise – Documentation requirements

10:15

10:45

Chapter 2 – The Deming Cycle & 8 QMS Principles

10:45

11:30

Team Exercise – Customer Focus

11:30

12:00

Lunch Break

12:00

1:00

Chapter 3 – Process Approach (includes multiple exercises and role play scenarios)

1:00

4:00

Daily Wrap-up

4:00

4:30

 DAY TWO

Title

Start

Finish

Day 2 Ice Breaker – summarize past day learning

8:00

8:15

Chapter 3.5 – APQP, Control Plan and PPAP

8:15

10:00

Break

10:00

10:15

Team Exercise – PPAP Case Study – Control Plan

10:15

10:45

Chapter 3.5 – APQP, Control Plan and PPAP - continued

10:45

12:00

Lunch break

12:00

1:00

Chapter 4 – Risk and Problem Solving

1:00

2:00

Team Exercise – PPAP Case Study- FMEA

2:00

2:30

Coffee break

2:30

2:45

Chapter 4 – Risk and Problem Solving – continued

2:45

3:15

Team Exercise – Pokayoke

3:15

4:00

Daily Wrap-up

4:00

4:30

DAY THREE

Title

Start

Finish

Day 3 Ice Breaker – summarize past day learning

8:00

8:15

Chapter 5 – Variation -MSA

8:15

9:00

Team Exercise – PPAP Case Study –MSA

9:00

9:30

Coffee Break

 9:30

9:45

Chapter 5 – Variation -SPC

9:45

10:30

Team Exercise – PPAP Case Study –SPC

10:30

11:00

Chapter 6 – Waste and Lean Manufacturing

11:00

12:00

Lunch Break

12:00

1:00

ISO/TS 16949 Quiz

1:00

2:00

Chapter 7 – Audit Trails & Role Play Exercise

2:00

2:30

Coffee break

2:30

2:45

Chapter 8 – Nonconformances and Team Exercise

2:45

4:30

DAY FOUR

Title

Start

Finish

Closing Meeting Role Play – PresentNCRResults

8:00

10:00

Coffee break

10:00

10:15

Chapter 9 – Corrective Actions and Team Exercise

10:15

11:00

Chapter 10 – Audit Reporting

11:00

11:30

Chapter 11 – Audit Program Management

11:30

12:00

Lunch Break

12:00

1:00

Chapter 12 – Approach to the Audit

1:00

1:30

Course Conclusions and Student Feedback

1:30

2:00

Exam

2:00

4:00

 NOTE: All PPAP case study exercises also include instructor led role play scenarios

Click here to launch our Course Registration Form.

New Public Training Dates Announced

ISO/TS 16949:2009 Internal Lead Auditor Training (32hrs)

September 12-15, 2011 - Columbus, IN October 24-27, 2011 - Charleston, SC November 14-17, 2011 - Columbus, IN December 12-15, 2011 - Charleston, SC

Course Description

This advanced course caters to the full spectrum of ISO 9001 and ISO/TS 16949 auditor responsibilities – from auditing using the most effective automotive process approach to audit program management.  If you are looking for a Lead Auditor course for internal processes or supplier quality development with a focus on the automotive process auditing and use of the AIAG core tools, look no further. This course is for you!

This course will teach you the fundamental tools necessary to conduct audits and provide vital strategic information for SELLING your findings to top management in order to improve organizational objectives. You will also learn the requirements associated with properly addressing nonconformities to prevent recurrence and pro-active techniques for evaluating business risks. Real world tools, case studies and scenarios make this course a challenge, but a lot of fun.

This course meets or exceeds the training requirements for:

  • Ford Customer-specific Internal Quality Auditor requirements
  • General Motors Customer-specific Internal Quality Auditor requirements

Length: 4 days/32 hours CEUs: 3.2 A certificate will be given upon successful completion of all course requirements.

ISO/TS 16949:2009 Internal Lead Auditor Training (32hrs): $1495*

*Price include training materials and training facilities for each student. SEND TWO STUDENTS & THE THIRD STUDENT ADMISSION IS FREE with our 30-day Pre-Pay Option!  To register, reach us by email at jim.thompson@cmsicharleston.com or by calling 843.469.8279.

All of our instructors are accredited with extensive industry expertise in the respective course(s) they teach. CVs/Resumes can be provided upon request at any time. To register, complete our Course Registration Form, contact us by email at jim.thompson@cmsicharleston.com or by calling 843.469.8279.

Course Agenda

DAY ONE - Process Approach and Automotive Core Tools

Session Title Start Finish
1 Chapter 1 - Course Introduction 8:00 8:30
2 Interview Exercise 8:30 9:15
3 Chapter 2 – The Deming Cycle & 8 Principles 9:15 10:00
4 Coffee Break 10:00 10:15
5 Chapter 3 – Process Approach 10:15 12:00
6 Lunch Break 12:00 1:00
7 Chapter 4 – Risk and Problem Solving 1:00 2:30
8 Chapter 5 – Variation 2:30 3:00
9 Coffee break 3:00 3:15
10 Chapter 5 – Variation - continued 3:15 4:30
11 Daily Wrap-up 4:30 5:00

DAY TWO - Review of ISO/TS 16949 Standard

Session Title Start Finish
1 Day 2 Ice Breaker – summarize past day learning 8:00 8:15
2 Chapter 6 – Waste and Lean Manufacturing 8:15 9:00
3 Chapter 6.5 – Overview of ISO/TS 16949 9:00 10:00
4 Coffee break 10:00 10:15
5 Chapter 6.5 – Overview of ISO/TS 16949– continued 10:15 12:00
6 Lunch break 12:00 1:00
7 Chapter 6.5 – Overview of ISO/TS 16949– continued 1:00 3:00
8 Coffee break 3:00 3:15
9 Chapter 6.5 – Overview of ISO/TS 16949– continued 3:15 4:30
10 Daily Wrap-up 4:30 5:00

DAY THREE - Review of ISO/TS 16949 Standard - continued and Auditing Basics

Session Title Start Finish
1 Chapter 6.5 – Overview of ISO/TS 16949– continued 8:00 10:00
2 Coffee Break 10:15 10:30
3 Chapter 6.5 – Overview of ISO/TS 16949– continued 10:30 12:00
4 Lunch Break 12:00 1:00
5 ISO/TS 16949 Quiz 1:00 2:00
6 Chapter 7 – Audit Trails & Exercise 2:00 3:00
7 Coffee break 3:00 3:15
8 Chapter 8 – Audit Program Management 3:15 3:30
9 Chapter 8 – Audit Scheduling Workshop 3:30 4:15
10 Chapter 8 – Audit Program Management - cont. 4:15 5:00

DAY FOUR - Auditing Basics - continued and Exam

Session Title Start Finish
1 Chapter 9 – Audit Reporting 8:00 8:45
2 Chapter 10 – Nonconformances 8:45 9:00
3 NCR Case Studies Workshop 9:00 10:00
4 Coffee break 10:00 10:15
5 Chapter 11 – Corrective Actions 10:15 11:15
6 Corrective Actions workshop 11:15 12:00
7 Lunch Break 12:00 1:00
8 Chapter 12 – Approach to the Audit 1:00 1:30
9 Course Conclusions and Student Feedback 1:30 2:00
10 Exam 2:00 4:00

Click here to launch our Course Registration Form.