| name | Internalaudit |
| description | Support IATF 16949 internal audit programme - QMS audits, process audits, product audits, and layered process audits. Covers audit planning, checklists, findings, and corrective actions. USE WHEN user says 'internal audit', 'audit checklist', 'process audit', 'product audit', 'QMS audit', 'audit finding', 'nonconformance', or 'LPA'. Integrates with AutomotiveManufacturing and A3criticalthinking skills. |
| effort | medium |
Internal Audit
When to Activate This Skill
- "Plan internal audit programme"
- "Create audit checklist for [process/area]"
- "Conduct process/product/QMS audit"
- "Document audit findings"
- "Write nonconformance report"
- "Plan layered process audit (LPA)"
- "Prepare for IATF 16949 certification audit"
IATF 16949 Audit Requirements
Clause 9.2.2.1 - Internal Audit Programme
The organization shall:
- Maintain documented internal audit programme
- Cover all QMS processes over audit cycle (typically 3 years)
- Include customer-specific requirements (CSRs)
- Consider process risk and previous audit results
- Define audit criteria, scope, frequency, methods
Types of Internal Audits
IATF 16949 requires three types of internal audit (clauses 9.2.2.2–9.2.2.4):
| Audit Type | Focus | Frequency | Reference |
|---|
| QMS Audit | Management system conformance to IATF 16949/ISO 9001 | Annual minimum per clause | 9.2.2.2 |
| Process Audit | Manufacturing process effectiveness (process approach) | Based on risk, min annual | 9.2.2.3 |
| Product Audit | Product conformance at production/delivery stages | Per control plan, min annual | 9.2.2.4 |
Note: Layered Process Audits (LPA) are not a standalone IATF 16949 requirement. They are a customer-specific requirement (CSR) from certain OEMs (e.g., GM, Ford, Stellantis). They must be implemented when required by customer CSRs but are separate from the three IATF-mandated audit types above.
QMS Audit (9.2.2.2)
Purpose
Verify conformance to IATF 16949/ISO 9001 requirements and organization's QMS.
Scope
All clauses of IATF 16949 over the audit cycle:
- Context of organization (4)
- Leadership (5)
- Planning (6)
- Support (7)
- Operation (8)
- Performance evaluation (9)
- Improvement (10)
Approach
- Clause-based checklist
- Interview management and staff
- Review documented information
- Verify implementation and effectiveness
Output
- Completed checklist
- Finding report (NCRs, OFIs)
- Audit report
Process Audit (9.2.2.3)
Purpose
Evaluate effectiveness of manufacturing processes using process approach.
Scope
Each manufacturing process including:
- Inputs and outputs
- Process controls
- Operator competence
- Equipment capability
- Work instructions compliance
Approach - Turtle Diagram Method
INPUTS OUTPUTS
↓ ↑
Materials, specs Products, data
↓ ↑
┌─────────────────────────────┐
│ │
WITH → │ PROCESS BEING │ → METRICS
WHAT? │ AUDITED │ KPIs met?
│ │
└─────────────────────────────┘
↑ ↑
WHO? HOW?
Competent? Per procedure?
Key Questions
- Are inputs conforming?
- Are process parameters controlled?
- Are operators competent and trained?
- Is equipment maintained and capable?
- Are work instructions followed?
- Are outputs conforming?
- Are KPIs being met?
Product Audit (9.2.2.4)
Purpose
Verify product conformance at appropriate stages of production and delivery.
Scope
- Dimensional verification vs. drawing
- Functional testing vs. specification
- Appearance vs. standards
- Packaging and labeling
- Documentation/traceability
Approach
- Select sample per Control Plan
- Measure against all drawing requirements
- Verify special characteristics
- Check packaging and identification
- Document all measurements
Frequency
- At defined stages (per Control Plan)
- All special characteristics covered annually
- After process changes
Layered Process Audit (LPA)
Purpose
Standardized process verification at multiple organizational levels.
Structure
| Level | Auditor | Frequency | Scope |
|---|
| Level 1 | Team Leader | Daily | Key process steps |
| Level 2 | Supervisor | Weekly | Process area |
| Level 3 | Manager | Monthly | Department |
| Level 4 | Plant Manager | Monthly | Multiple areas |
Key Characteristics
- Same checklist at all levels
- Focus on standardized work
- Quick (10-15 minutes)
- Immediate corrective action
- Trend tracking
Audit Planning
Annual Audit Schedule
Consider:
- All QMS processes over cycle (max 3 years)
- All manufacturing processes annually
- Risk-based frequency (high risk = more frequent)
- Previous audit results
- Customer complaints
- Internal quality performance
- Changes to processes
Audit Plan Elements
| Element | Description |
|---|
| Audit number | Unique identifier |
| Date | Scheduled date |
| Scope | What will be audited |
| Criteria | Requirements to audit against |
| Auditor(s) | Qualified auditor assignment |
| Auditee | Process owner/department |
| Duration | Expected time |
Auditor Qualification
Requirements (per 9.2.2.2)
- Understanding of automotive process approach
- Customer-specific requirements knowledge
- ISO 19011 audit principles
- Core tools knowledge (FMEA, SPC, MSA)
- IATF 16949 requirements knowledge
Independence
- Auditors shall not audit their own work
- Cross-functional audit teams encouraged
- External auditor for sensitive areas
Training Path
- Internal training on QMS and IATF 16949
- Core tools training
- Audit technique training
- Shadow audits (observe experienced auditor)
- Supervised audits
- Independent auditor status
Conducting the Audit
Opening Meeting
- Confirm scope and schedule
- Explain audit method
- Confirm resources and access
- Answer questions
Evidence Collection
- Interview personnel
- Review documents and records
- Observe processes
- Take notes with objective evidence
Audit Techniques
- Open-ended questions (How? What? Why?)
- Request evidence for claims
- Follow the trail (traceability)
- Verify vs. specification
- Compare to procedure
Closing Meeting
- Present findings
- Confirm accuracy with auditee
- Agree on corrective action timelines
- Thank participants
Finding Classification
Major Nonconformance
Definition: Absence or complete breakdown of system to meet requirement, or situation likely to result in shipping nonconforming product.
Examples:
- No documented procedure when required
- Consistent failure to follow procedure
- Pattern of nonconforming product
- Missing required records
Action: Requires root cause analysis, corrective action, and verification before certification.
Minor Nonconformance
Definition: Single lapse in meeting a requirement; does not affect product quality or system integrity.
Examples:
- Isolated instance of missing signature
- Minor record-keeping gap
- Single deviation from procedure
- Incomplete training record
Action: Requires correction, may require root cause and corrective action.
Opportunity for Improvement (OFI)
Definition: Not a nonconformance, but improvement recommendation.
Examples:
- Better organization possible
- More efficient method available
- Good practice from other areas
- Proactive enhancement
Action: Optional implementation, tracked for consideration.
Corrective Action Process
Timeline Requirements
| Finding | Initial Response | Corrective Action | Verification |
|---|
| Major | 24-48 hours | 30 days max | Within 90 days |
| Minor | 5 business days | 60 days max | Within 90 days |
| OFI | 30 days | As appropriate | As appropriate |
Corrective Action Elements
- Containment: Immediate action to contain impact
- Root Cause: Analysis to determine true cause (5-Why, Fishbone)
- Corrective Action: Action to eliminate root cause
- Implementation: Execute corrective action
- Verification: Confirm effectiveness
- Prevent Recurrence: Systemic changes
Output Format
Audit Report Structure
# Internal Audit Report
## Audit Information
| Field | Value |
|-------|-------|
| Audit Number | IA-[YYYY]-[SEQ] |
| Type | QMS / Process / Product |
| Date | [YYYY-MM-DD] |
| Auditor(s) | [Names] |
| Auditee | [Name/Department] |
| Scope | [Description] |
## Executive Summary
[Brief summary of audit results]
## Findings Summary
| Major NC | Minor NC | OFI | Positive Findings |
|----------|----------|-----|-------------------|
| [count] | [count] | [count] | [count] |
## Detailed Findings
### Finding 1: [Title]
**Classification:** Major / Minor / OFI
**Requirement:** [Reference]
**Evidence:** [Objective evidence]
**Finding:** [Description]
**Response Due:** [Date]
[Repeat for each finding]
## Positive Observations
[Good practices observed]
## Conclusions
[Overall assessment]
## Approvals
| Role | Name | Signature | Date |
|------|------|-----------|------|
| Lead Auditor | | | |
| Quality Manager | | | |
Examples
Plan an audit programme:
"I need to create our annual internal audit schedule for IATF 16949 — what processes should I prioritise and how do I structure the programme?"
→ Generates risk-based audit schedule covering all QMS processes over the 3-year cycle with frequency guidance.
Create a process audit checklist:
"Create a turtle diagram-based process audit checklist for our CNC machining area"
→ Produces structured checklist with inputs, outputs, who, what, how, and KPI sections tailored to CNC machining.
Document an audit finding:
"I found that 3 operators have no training records for the revised work instruction WI-MS-023 — write up the nonconformance"
→ Generates a properly structured NCR with requirement reference, objective evidence, classification (Major/Minor), and corrective action timeline.
Set up an LPA programme:
"We have a Ford CSR requiring layered process audits — help me set up our LPA programme with 4 layers"
→ Creates LPA structure, sample checklist items, frequency matrix, and metrics tracking approach.
Workflow Routing
| User Intent | Audit Type | Key Outputs |
|---|
| "Audit the QMS / system audit" | QMS Audit (9.2.2.2) | Clause-based checklist, audit report |
| "Audit the machining/welding/assembly process" | Process Audit (9.2.2.3) | Turtle diagram checklist, process findings |
| "Check product conformance / product audit" | Product Audit (9.2.2.4) | Dimensional/functional checklist, sampling plan |
| "Daily/layered process audit / LPA" | Layered Process Audit (CSR) | LPA checklist, tier structure, trend metrics |
| "Plan audit schedule / audit programme" | Audit Planning | Annual schedule, coverage matrix, risk ranking |
| "Write up a finding / NCR" | Finding Documentation | NCR with evidence, classification, timeline |
| "Prepare for certification / IATF audit" | Cert Preparation | 6/3/1 month checklists, common findings list |
Integration with Related Skills
AutomotiveManufacturing
Process audits verify work instruction compliance:
- Are documented procedures being followed?
- Are quality checkpoints being executed?
- Are records being maintained?
Load: read ~/.claude/skills/Automotivemanufacturing/SKILL.md
A3criticalthinking
For audit finding root cause analysis:
- Use 5-Why methodology
- Fishbone diagram for complex issues
- A3 format for corrective action plans
Load: read ~/.claude/skills/A3criticalthinking/SKILL.md
Supplementary Resources
For detailed guidance:
read ~/.claude/skills/Internalaudit/CLAUDE.md
For checklists:
ls ~/.claude/skills/Internalaudit/templates/
For IATF clause questions:
read ~/.claude/skills/Internalaudit/reference/iatf-clause-questions.md
