A Case Study: Framework of Gap Analysis on Integration of Audit System between IATF 16949 and Toyota Production System

摘要

This paper presents a case study on a research framework of gap analysis on audit systems for a standard called IATF 16949 and Toyota Production System (TPS) in the automotive industry. A study was carried out to define the gaps that are currently being faced in this industry. A comparison and contrast for an audit process flow chart was plotted and showed that there are processes have similar audit objectives, same auditees and involved with the same documents to be audited. Meanwhile, 5M (Man, Machine, Method, Material, Measurement and) 1 E (Environment) methodology were used to study audit requirements for both IATF 16949 and TPS and showed that both systems share the same audit items. Rasch model was used to measure the level of satisfaction, difficulties, and challenges faced by the people in the industry. By reducing the few steps in implementing the internal audit, it is expected to minimize the “wastes” that occurred during the execution of both audit systems. This case study has proposed that the integration of audit system of the IATF 16949 and TPS will harmonize the systems and reduce the hassle faced by the people in the industry.