[Checklists] Internal Audit IATF 16949

structured matrix for IATF 16949 internal audits, linking clauses, checklist questions, evidence required, and automotive-specific examples:

IATF 16949 Internal Audit Matrix

(Aligned with ISO 9001:2015 structure + IATF specific requirements)

Clause	Checklist Question	Evidence to Review	Automotive Example	Compliance (✔/✖)
4.1 Context	Has the organization identified internal/external issues affecting QMS?	SWOT analysis, PESTLE report.	OEM demand shifts to EVs impacting supply chain.	✔
5.1 Leadership	Does top management review customer scorecards (PPM, OTIF)?	Management review records, customer dashboards.	Review of Ford’s monthly quality scorecard.	✔
6.1 Risks	Are risks updated post-FMEA or recall?	Risk register, FMEA updates, 8D reports.	Updated PFMEA after battery connector recall.	✖ (Overdue)
7.1.5.1 MSA	Is GR&R ≤10% for critical characteristics?	MSA reports, gauge calibration records.	Caliper GR&R for hood thickness measurement.	✔
8.3.5.1 APQP	Is APQP on schedule for new projects?	APQP timelines, phase-gate review minutes.	Delayed Phase 4 (Validation) for Tesla bumper.	✖
8.5.1 SPC	Are control charts active for CCs (CpK ≥1.33)?	X-bar R charts, reaction plans.	Stamping force SPC out-of-control (no action).	✖
8.7.1 NC	Are containment actions implemented within 24hrs?	Containment records, quarantine logs.	Held 200 defective headlamps (no root cause).	✖
9.1.2 Customer Satisfaction	Is customer feedback analyzed quarterly?	Survey results, warranty claims analysis.	Toyota’s Q3-2023 defect trend report.	✔
10.2.1 CAPA	Are CAPAs closed within 30 days?	CAPA log, verification records.	Open CAPA #45 (45 days overdue).	✖

Automotive-Specific Focus Areas

1. Process Audits (VDA 6.3)

   • P2-P7: Verify project planning, production controls (e.g., weld validations).

   • Evidence: Process FMEAs, control plans, operator certifications.

2. CSRs (Customer-Specific Requirements)

   • Example: Ford’s Q1 Certification for suppliers.

   • Evidence: CSR compliance matrix, audit reports.

3. Traceability

   • Clause 8.5.2: Full traceability for recalls (e.g., VIN-based tracking).

   • Evidence: Material batch logs, serial number records.

Evidence Types & Examples

Evidence Category	Examples
Documentation	Control Plans, FMEAs, PPAP submissions, SOPs.
Records	MSA reports, SPC charts, training logs, calibration certs.
Observations	Gemba walk findings, 5S compliance, visual management.
Digital	ERP/MES data (OEE, downtime), IoT sensor alerts.

Non-Conformance (NC) Grading

NC Level	Criteria	Example
Major	Impacts product safety/regulatory compliance.	No PFMEA for brake component (IATF 6.1.2.3).
Minor	Isolated lapse without systemic impact.	Missing calibration sticker on 1 gauge.
Opportunity for Improvement (OFI)	Best practice gaps.	No automated SPC alerts in press shop.

Audit Workflow

1. Plan: Focus on high-risk areas (e.g., CCs, recalls).

2. Check: Use checklists + VDA 6.3 for process audits.

3. Report: Document NCs with evidence (photos, screenshots).

4. Follow-up: Verify CAPA effectiveness in 30 days.

Templates & Tools

• Audit Checklist Template: [Download Link]

• VDA 6.3 Questionnaire: [Example]

• Automated Tools: Intelex, Qualio, Siemens Teamcenter.

Need sector-specific checklists (e.g., Casting, Electronics) or CAPA