[Checklists] IATF 16949

checklists for IATF 16949 compliance, tailored to key clauses and Core Tools. These ensure systematic audits and implementation:

1. APQP (Advanced Product Quality Planning) Checklist

Phase 1: Plan & Define

• Customer requirements (VOC) documented (e.g., OEM specs, warranty data).

• Initial risk assessment completed (PFD, SWOT).

• Cross-functional team assigned (Engineering, Quality, Production).

Phase 2: Product Design

• DFMEA reviewed/updated (RPNs prioritized).

• Design reviews conducted (CAD simulations, prototypes).

• Critical characteristics (CC/SC) identified.

Phase 3: Process Design

• PFMEA completed (RPN <100 for high-severity items).

• Control Plan drafted (inspection frequencies, reaction plans).

• MSA plan for gauges defined (GR&R <10%).

Phase 4: Validation

• PPAP submitted (including PSW, MSA, CpK data).

• Pilot run conducted (OTS/ISIR approved).

• Lessons learned documented.

Phase 5: Feedback & Launch

• SPC charts implemented for CCs (CpK ≥1.33).

• Customer sign-off received.

2. PPAP (Production Part Approval Process) Checklist

Documentation

• Part Submission Warrant (PSW) signed.

• Design records (CAD, specifications).

• Process Flow Diagram and Control Plan.

Evidence

• MSA reports (GR&R ≤10% for critical dimensions).

• Initial Process Study (CpK/PpK ≥1.67 for new processes).

• Material/certification of compliance (RoHS, REACH).

Validation

• 300+ consecutive parts produced without deviations.

• Dimensional reports (100% inspection for CCs).

• Packaging approved (ISTA 3A tested if required).

3. FMEA (PFMEA/DFMEA) Checklist

Preparation

• Cross-functional team engaged (Process Eng., Quality, Operators).

• Process Flow Diagram (PFD) validated.

Risk Analysis

• All failure modes listed (including potential supplier defects).

• Severity (S), Occurrence (O), Detection (D) scored (1-10).

• RPN calculated (S × O × D); actions for RPN >100.

Actions

• Mitigation plans for high RPNs (e.g., error-proofing, enhanced inspections).

• Updated Control Plan linked to FMEA.

4. MSA (Measurement System Analysis) Checklist

Preparation

• Critical characteristics identified for MSA.

• Operators (3) and parts (10) selected for GR&R.

Execution

• GR&R study completed (%GR&R ≤10% for critical dimensions).

• Bias, linearity, and stability assessed (if applicable).

Results

• Out-of-tolerance gauges recalibrated/replaced.

• MSA report archived for audits.

5. SPC (Statistical Process Control) Checklist

Setup

• Critical characteristics (CCs) mapped to Control Plans.

• Control chart type selected (X-bar R for variables, p-chart for attributes).

Monitoring

• Data collected per frequency in Control Plan.

• Out-of-control signals (e.g., 7-point trend) trigger reaction plans.

Improvement

• CpK/PpK tracked monthly (target ≥1.33).

• Corrective actions documented for CpK <1.0.

6. Internal Audit Checklist (IATF 16949 Clauses)

Context & Leadership (Clause 4-5)

• Quality policy communicated to all employees.

• Risks/Opportunities register updated.

Operations (Clause 8)

• Change management records (e.g., ECOs) reviewed.

• Temporary process changes documented (e.g., deviations).

Performance Evaluation (Clause 9)

• Management review minutes include COPQ analysis.

• Customer scorecards (PPM, OTIF) reviewed.

Improvement (Clause 10)

• CAPAs closed within 30 days.

• Lessons learned from recalls/non-conformities applied.

7. Layered Process Audit (LPA) Checklist

Daily/Weekly Checks

• PPE compliance (gloves, safety glasses).

• Calibration stickers on gauges valid.

• Work instructions visible and up-to-date.

Monthly Checks

• 5S adherence (workstation organization).

• Control Plan followed (e.g., inspection logs).

Key Notes for Implementation

• IATF 16949 Alignment: Each checklist maps to clauses (e.g., PFMEA → 6.1.2.3, MSA → 7.1.5.1).

• Automotive Focus: Prioritize CCs (Critical Characteristics) and customer-specific requirements (CSRs).

• Digital Tools: Use software like IQMS, Qualio, or Minitab to automate checklists.