Understanding The ISO/TS 16949:2002 Standard 

7.5.1.4  Preventive & Predictive maintenance  

Identify key process equipment & provide resources for their maintenance. Develop an effective planned total preventive maintenance system which as a minimum shall include: 

- planned maintenance activities;  

- packaging & preservation of equipment; 

- packaging & preservation of equipment, tooling & gauging 

- replacement parts for key manufacturing equipment 

- documenting, evaluating & improving maintenance objectives 

Use predictive maintenance methods to continually improve the effectiveness & efficiency of equipment

Key Explanation Points and Tips: 

Þ      See notes under clause 6.3 

Þ      Perform a FMEA on the various types of process equipment you use, to identify key process equipment to include in your program for planned total preventive maintenance system. Consider doing this by equipment groups, if all equipment within a group operates in the same way. Identify maintenance as a process within your QMS as per clause 4.1, including any outsourced maintenance activities. 

Þ      Your planned preventive maintenance program should include – schedule and timing; availability and training of personnel; types and scope of maintenance; records; tracking to maintenance objectives; use, storage and control of spare parts; control of any maintenance outsourcing; etc. There are many software programs available to help do this. 

Þ      Predictive maintenance methods should include a review of manufacturer’s recommendations; storage; tool wear; optimization of uptime; correlation of SPC data to predictive maintenance activities; important characteristics of perishable tooling; fluid analysis; monitoring of circuits; and vibration analysis. Check sub-clause 3.1.7 and 3.1.8 under Terms and Definitions - clause 3 of this standard. Review specific requirements for maintenance at OEM customer or IATF websites. 

Þ      Include, as appropriate, maintenance of equipment in your control plans. 

7.5.1.5 Management of production tooling 

Provide resources for tool & gauge design, fabrication & verification activities 

Use a tooling management system that includes: 

Þ     Maintenance & repair facilities & personnel 

Þ     Set-up, storage and recovery  

Þ     Tool change programs for perishable tools 

Þ     Documentation for tool design modification, including engineering change level 

Þ     Tooling identification that defines status, such as production, repair or disposal 

  Implement a system to monitor these activities, if any of them is outsourced. 

Note:   Tooling management also applies to availability of tools for vehicle service parts 

Key Explanation Points and Tips: 

Þ      Tooling and tooling management may be a significant part of your product realization. Tooling includes tooling for production as well as vehicle service parts. Consider doing a FMEA’s for tooling design, fabrication, verification, storage, set-up and operation. You will be surprised how much you will discover and much more effective and efficient your tooling operations will become.     

Þ      You must include tooling and its sub-processes within the scope of your QMS (see 4.1). Make sure you document the interaction of tooling with other processes such as design, purchasing, production, maintenance, etc. This includes outsourcing of any of the tooling processes. Review specific requirements for tooling management at OEM customer or IATF websites. 

Þ      Make sure you have appropriate records for competency and training of tooling personnel, as well as records for effective planning, operation and control of each activity listed in clause 7.5.1.5. 

Þ      The system you use to monitor any outsourcing must be similar to the controls required if done in-house and you will be required to show evidence of such controls over outsourced work. Customer provided tooling and equipment must be marked or identified as such (see clause 7.5.4.1). 

Þ      Reference appropriate tooling and equipment in your control plans and/or work instructions. 

7.5.1.6 Production Scheduling 

You shall schedule production to meet customer requirements such as just-in-time supported by an information system that provides access to production information at key stages. Production scheduling shall be order driven 

Key Explanation Points and Tips: 

Þ      Your production scheduling must be order-driven. Use methods such as just in time; material requirements planning; customer EDI; use of pull systems; small lots for one piece flow; etc, to manage and achieve this.  

Þ      Carefully define and document the interaction of your production scheduling process with your logistics processes such as inventory management; customer communication; traffic and shipping control; packaging and labeling; sales and billing. 

7.5.1.7 Feedback of service information 

Have a process to communicate information on service concerns to design, engineering & manufacturing activities. 

Note:   The intent of this sub-clause is to ensure your organization is aware of nonconformities that occur externally. 

Key Explanation Points and Tips: 

Þ      Define and document your process to provide feedback to production, engineering and design. This should include feedback from OEM’s; customers; as well as vehicle owners through auto dealerships and industry/regulatory research/focus organizations.  

Þ      You are required to evaluate failures and concerns from the field. You must consider either an immediate corrective action (i.e. a recall for a safety or regulatory violation) or review them through your APQP process and update, as appropriate, your product specifications FMEA’s; control plans, work instructions, PPAP, etc.  

7.5.1.8 Service agreement with customer 

Where there is a service agreement with your customer , you shall verify the effectiveness of: 

Þ      Your service centers 

Þ      Any special purpose tools or measurement equipment 

Þ      Training of service personnel 

 Key Explanation Points and Tips: 

Þ      If you have a service agreement with an OEM customer either to service product under warranty or even past warranty, then you must make available appropriate resources for such services. These services may be performed at your customer or your own facilities. 

Appropriate resources include space; transportation; special purpose tools; diagnostic and measurement equipment; replacement parts and components; availability and use of competent personnel. Don’t forget to include this process within your QMS as per clause 4.1