Integration of IATF 16949 and Toyota production system audit requirements in an automotive assembly line / Qhairunisha Mohd Khalid

This research presents a case study on the integration of International Automotive Task Force (IATF) 16949 and Toyota Production System (TPS) audit requirements in an automotive assembly line. Redundancy of documents used at production floor has caused the difficulty in analysing the actual data taken by people at production. This is due to similar record sheets being used for both IATF 16949 and TPS with the same function and objective of the documents. The separate Quality Management System (QMS) has led to inefficiency of Internal Quality Audit due to the missed match between parameters and audit requirements in IATF 16949 and TPS. With the main objective to develop a framework that can harmonize both systems, this research was executed based on five main stages which were Plan, Analyse, Design, Implement and Evaluate. This is a revolutionized version of the famous model and approach of Deming’s Cycle or Plan-Do-Check-Act (PDCA) Cycle and Toyota’s 8’s steps process. Research was carried out to define the gaps and problems faced by this organization. A comparison and contrast for a QMS between IATF 16949 and TPS were plotted and it showed that the processes had similar elements, tools and process objectives which involved similar documents applied in the organization on daily tasks. Survey questionnaire was used and distributed to the people involved in the organization. This is to gauge the level of satisfaction, difficulties, and challenges faced by the people in the organization.