Start at the line: a quick shop‑floor snapshot

• How many production lines or shifts does your plant run? Options: 1 line, single shift, 1 line, multiple shifts, 2-4 lines, 5+ lines
• Describe the product families made on these lines, and any frequent changeovers that increase risk.
• Which quality metrics do you monitor daily on the shop floor? Options: PPM (parts per million), Scrap rate, First pass yield, Incoming defects, Customer complaints, Internal nonconformances, Other
• Walk me through the last OEM audit finding that required immediate work, what was it and where did it show up?
• What would make you pause a certification effort at this plant right now?

Where quality actually fails

• If you had to name the one control that most often fails when production is busy, what would it be?
• How many controlled‑shipping or customer‑directed inspections did you have in the last 12 months? Options: None, 1–2, 3–5, 6–12, More than 12
• What happens downstream when that control fails, and who absorbs the cost? Options: Rework on site, Scrap, Customer hold or return, Warranty claim, Line stoppage, Other
• Who first notices these failures on a typical day? Options: Operator, Line inspector / QA, Line supervisor, Engineering, Customer surveillance, Other
• What threshold, in PPM or repeat nonconformities, would make you escalate to plant leadership and halt rollout?

The paperwork versus what actually happens on the floor

• When you compare your documented control plans to what operators actually do, where do they diverge most often?
• Which documents most frequently change after an audit or a line change? Options: Control plan, FMEA, Standard work / work instructions, PPAP/FAI packages, Inspection plans, Training records, Other
• Walk me through a recent instance where a procedure existed but the shop floor did not follow it, what stopped compliance?
• How long does it typically take to update and reissue a control plan and train operators on it? Options: <1 week, 1–2 weeks, 3–4 weeks, 5–8 weeks, Longer than 8 weeks
• If we proved a repeatable way to close that gap inside 12 weeks, what would stop you from approving a pilot?

Evidence, audits, and the patterns they reveal

• Which OEM audit finding reappears most often across your plants? Options: Process control/SPC gaps, FMEA not updated, Control plan gaps, Training records incomplete, PPAP/FAI issues, Internal audit program gaps, Other
• When your internal audit program runs, how many major and minor nonconformities do you average per plant per year? Options: 0–2, 3–6, 7–12, More than 12, We do not run regular internal audits
• Tell me about the last FAI or PPAP that was rejected or required resubmission, what caused the failure?
• Who currently prepares and owns audit evidence for external auditors at the site? Options: Quality manager, QA engineers, Operations/line supervisor, Document control, Shared team, Other
• What single audit finding, if fixed, would most improve your chance of passing a registrar audit on the first try?

Constraints and practical blockers we must surface

• Which integration, access, or data gap would prevent us from collecting shop‑floor inspection data in week one?
• Which systems hold your quality data today? Options: MES, ERP, Standalone quality software, Spreadsheets, Paper records, Homegrown database, Other
• Do you have named site owners and a dedicated implementation contact ready to commit time during production windows? Options: Yes, named and available, Named but limited availability, No, will assign if project starts, Unsure
• Who owns API or integration work in your IT organization and can grant access?
• Is there any regulatory, union, or OEM approval that could block field changes during the proposed timeline? Options: Yes, OEM approval required, Yes, union/work rules constrain changes, Yes, regulatory permit needed, No known blockers, Unsure

Who signs, who champions, and who pushes back

• Who would have final approval to sign a supplier engagement scoped at this plant?
• Which stakeholders must be convinced for a pilot to proceed? Options: Quality leadership, Plant manager, Operations/production, Finance, Procurement, IT, Engineering, Other
• Describe the metrics each stakeholder cares most about for a successful outcome.
• How quickly can finance approve an unplanned spend under $50k to start a pilot? Options: Immediately with PO, Within 2 weeks, 2–6 weeks, Longer than 6 weeks, Not possible without budget cycle
• Who could kill the pilot during execution and what would make them do that?

Competitive landscape, the options you are weighing

• Which of the following options are you seriously considering right now? Options: Keep current process and self‑fix, Renew with incumbent consultant, Engage a new external consultant, Software only solution, Build an in‑house tool, Work directly with certifier for guidance, Other
• If you stayed with your current approach, what evidence would need to appear to keep you from switching?
• Has anyone internally proposed solving the gaps without an outside partner? Options: Yes, with a dedicated internal project, Yes, but no resources committed, No internal proposal yet, Unsure
• Which vendor capabilities matter most in your selection? Options: Automotive/OEM supplier experience, Certifier acceptance of deliverables, Shop‑floor usability for operators, Integration and IT support, Training and change management, Price, Post‑certification sustainment
• What would tip the decision to an external partner this quarter rather than later?

Acceptance criteria and measurable signals that close the loop

• What one metric or piece of evidence would make you accept the system as ready for registrar review?
• Which of these acceptance gates do you require before billing or moving to stage two? Options: Internal audit with zero majors, SPC showing stable control for 30 days, Completed FMEA and updated control plans, Operator training completion >90%, Data integrations live and validated, PPAP/FAI accepted
• How many weeks of production data do you expect before accepting the change? Options: 2 weeks, 4 weeks, 8 weeks, 12 weeks, Depends on the part/process
• If the pilot shows the promised PPM reduction, would you be authorized to sign a broader rollout without another executive review? Options: Yes, No, Maybe, requires brief approval
• What's the fastest realistic decision window after a successful pilot, in business days or weeks? Options: 3 business days, 1–2 weeks, 3–4 weeks, 1–3 months, Longer

Practical next steps and timeline risks

• If we started discovery tomorrow, what single scheduling constraint would delay work beyond 30 days?
• When are your production windows for interventions in the next quarter? Options: Weekend shutdowns available, Planned maintenance weeks, Low volume days, Night shifts only, No windows available, Unsure
• Who needs to be present for the initial site interviews and working session? Options: Plant manager, Quality director, Production supervisor, Line operators, Maintenance lead, IT representative, Process engineering, Other
• Assuming the initial findings match expectations, how soon could you commit to a pilot start date? Options: Immediately, Within 2 weeks, 2–6 weeks, 6–12 weeks, Not ready
• Are there any non‑negotiable blackout dates in the next 90 days that would prevent workshops or installations? Options: Yes, major product launch week, Yes, OEM audit window, Yes, holiday or shutdown, Other specific dates, No blackout dates

• Assessment Kickoff and Evidence Alignment
• Shop-Floor Interviews and Current-State Process Mapping
• Document Evidence Review and Gap Classification
• Gap Prioritization and Remediation Planning Workshop
• Scope Decision and Validation Planning

• Publish the prioritized remediation plan including acceptance criteria and provisional timelines.
• Schedule any required follow-up measurement or MSA activities needed to validate findings.
• Agree prioritization criteria
• A prioritized remediation plan with provisional timelines for all high and medium priority gaps.
• Defined remediation actions and measurable acceptance criteria for each prioritized gap.
• A clear list of resource and dependency constraints to be addressed before implementation.
• Confirm scope and success criteria
• Document resource requests and any required scheduling constraints for implementation planning.
• List dependencies that must be resolved before remediation work begins.
• Review prioritized remediation plan
• A ratified list of in-scope remediation items for the implementation phase.
• A documented validation plan with specific evidence and acceptance checkpoints for each in-scope item.
• A clear handover schedule and required implementation inputs are recorded.
• Publish the final in-scope remediation list and the validation plan for use in the implementation scope.
• Prepare the implementation input package including timelines, owners, and acceptance criteria.
• Schedule the formal handover to the implementation planning session.
• A complete evidence checklist is agreed and dated for delivery.
• Named stakeholder contacts and production access windows are recorded.
• A detailed calendar of interviews and site walks is confirmed.
• Publish the agreed evidence checklist and delivery deadlines to the shared folder.
• Provide system access credentials or data export if required for document review.
• Confirm and publish the interview and site-walk schedule with participant names.
• Scope and mapping approach
• Deliverable current-state process maps for each targeted line or area.
• A consolidated list of observed control divergences and gaps in practice.
• A prioritized list of missing evidence items required for validation.
• Produce and share the current-state process maps with timestamped observations.
• Collect and upload any missing on-floor records or images identified during the walk.
• List and record all open questions requiring follow-up evidence or clarification.
• Recap field observations and evidence received
• A validated, classified gap list with evidence links for every finding.
• A short list of findings that require additional data or validation activities.
• Publish the classified gap list with evidence attachments and severity ratings.
• Request and collect specific missing evidence items or measurement data identified during classification.
• Identify stakeholders and access requirements
• Decide in-scope versus out-of-scope items
• Systematic review of control plans, FMEAs, PPAPs, and audit reports
• Line-by-line process walkthrough with operators
• Rank and time-box remediation for top gaps
• Define validation methods and acceptance checkpoints
• Agree evidence inventory and delivery plan
• Verify measurement and control practices
• Define remediation actions and acceptance criteria
• Classify each finding and link evidence
• Capture resource needs and dependencies
• Document discrepancies and open questions
• Identify items needing more data or validation
• Finalize interview and site-walk schedule
• Confirm next steps to Implementation Scope

• Solution Walkthrough — QMS Design & Operator Workflows

• Confirm the current state and its cost
• You confirm the demonstrated operator workflow prevents the recurring bypass and detection delays described in Discovery.
• Deliver a tailored QMS design packet for the agreed pilot process, including revised control plan, operator work instruction, and software workflow mockups.
• Map each high-priority gap to a QMS action
• You accept the mapped QMS changes (procedures, training, software) as sufficient to close the top 3 prioritized gaps for the pilot process.
• Provide a draft pilot acceptance checklist with measurable criteria (PPM threshold, closed nonconformities, required audit evidence) within five business days.
• Proof: Operator workflow walkthrough for a representative failure mode
• Provide the prioritized gap list, one representative control plan, and access to a shop-floor subject matter expert for the pilot walkthrough.
• You agree on pilot acceptance criteria that tie to measurable outcomes, such as PPM reduction target and required audit evidence.
• Confirm the decision committee members to include in the pilot review and the target pilot timeframe.
• Show training delivery and evidence capture
• Validate the proposed future state
• Agree pilot scope and acceptance criteria

• Solution Walkthrough — QMS Design & Operator Workflows
• Solution Experience Deck
• Solution Brief

• meeting
• slides
• document

• Deploy Quality Management Software Platform
• Migrate Quality Records from Existing Systems
• Create and Digitize Control Plans
• Digitize FMEA and Link to Control Plans
• Build PPAP Submission Packages
• Conduct MSA Gauge R&R Studies
• Implement SPC Data Collection and Control Charts
• Configure Nonconformance and Corrective Action Workflows
• Facilitate 8D Corrective Actions and Verification
• Develop Operator Work Instructions and Visual Controls
• Deliver Operator and Inspector Training Sessions
• Perform Pre-Certification Internal Audit
• Support Registrar Stage 1 and Stage 2 Audits
• Establish Supplier PPAP Review and Release Process
• Configure Management Review and Quality Dashboards

Deploy Quality Management Software Platform

• Which plants and shop floors will be included in the initial platform deployment (list plant codes or locations)?
• How many inspection templates and checklist types must be preloaded (for example incoming inspection, in-process operation checks, final inspection)? Options: <10, 10-50, 51-200, >200
• Do you require role-based access and auditor-level permission sets configured at go-live for operators, inspectors, engineers, and auditors? Options: Yes, No
• What integration endpoints must be connected at go-live (MES, ERP, machine PLCs, laboratory equipment, historian)?
• Who will be the designated platform administrator responsible for user provisioning, release approvals, and production-data stewardship?

Migrate Quality Records from Existing Systems

• When do you need legacy quality records migrated relative to project milestones (weeks before UAT, before pilot run, at go-live)? Options: Before UAT, Before pilot run, At go-live, Roll forward after go-live
• Where are the legacy records currently stored (shared drives, on-prem QMS database, spreadsheets, supplier portals)? Options: Shared drives, On-prem QMS database, Spreadsheets, Supplier portals, Other
• List the record types and approximate volumes to migrate (inspection records, NCRs, PPAP files, calibration certificates, MSA reports).
• Provide the key fields that must be preserved for traceability during migration (part number, lot number, operation, inspector ID, timestamp).
• Confirm the migration acceptance criteria you require (for example minimum percent completeness, preserved timestamps, traceability to part numbers). Options: Define acceptance criteria now, I need help defining criteria

Create and Digitize Control Plans

• Describe which part numbers or product families require new or revised control plans and include operation-level scope where possible.
• Is the control plan required to include reaction plans, sampling frequency, and OEM-designated special characteristic flags? Options: Yes, No
• Estimate how many special characteristics per part must be called out for OEM attention or customer-specific requirements. Options: None, 1-3, 4-10, >10
• Identify who in your engineering or quality organization will approve revised control plans and sign versions for release.
• Specify how revised control plans should be distributed to the shop floor (printed control boards, tablet push, operator acknowledgement workflow). Options: Printed control boards, Tablet push with acknowledgement, Email to supervisors, Combination

Digitize FMEA and Link to Control Plans

• Are DFMEA and PFMEA files available in editable format for digitization or must they be rebuilt from workshop notes? Options: Editable files available, Need rebuild from workshop
• Have current FMEA severity, occurrence, and detection scores been documented for the affected part numbers and revisions? Options: Yes, documented, Partially documented, No
• Will you require automatic task creation and owner assignment when an FMEA risk threshold is exceeded (for example RPN or Severity triggers)? Options: Yes, No
• How many cross-functional owners will maintain FMEA revisions and approve links to control plans (for example engineering, process, supplier quality)? Options: 1-2, 3-5, 6+
• Name representative failure modes that must be traced to operator controls and inspection steps in the digitized FMEA-control plan linkage.

Build PPAP Submission Packages

• Indicate the PPAP submission level required for each part number and any OEM-specific document expectations. Options: Level 1, Level 2, Level 3, Custom
• State which PPAP documents are mandatory for your customers (dimensional results, material certifications, control plan, FMEA, MSA studies, capability studies). Options: Dimensional results, Material certs, Control plan, FMEA, MSA studies, Capability studies, Other
• Outline the internal owner and sign-off workflow for the PPAP cover sheet and supplier statements of conformity.
• Supply the acceptance criteria you require for PPAP submissions (for example Cpk thresholds, complete dimensional reports, signed control plan). Options: Define acceptance criteria now, I need help defining criteria
• Select the target timing for PPAP submission relative to production start (before pilot run, before full production, after trial run). Options: Before pilot run, Before full production, After trial run

Conduct MSA Gauge R&R Studies

• Choose the measurement devices and gauge IDs requiring MSA studies, listing device ID and associated characteristic where possible.
• Give the preferred operator and part counts per gauge R&R study (for example 3 operators x 10 parts) for each gauge family. Options: 3 operators x 10 parts, 2 operators x 10 parts, Other
• Arrange whether you need MSA outputs formatted to IATF 16949 evidence including percent GRR, EV, and AV reporting. Options: Yes, No
• Assign who will provide calibration certificates and arrange physical access to gauges for on-site studies.
• Mark any gauges that require replacement, refurbishment, or external lab calibration before MSA begins. Options: None, List to be provided, All require check

Implement SPC Data Collection and Control Charts

• Record the process characteristics you want monitored with SPC control charts by line and shift (for example diameter, torque, hardness, cycle time).
• Attach the target subgroup sizes or sampling cadence for each characteristic (individuals, n=3, n=5, continuous capture). Options: Individuals, n=2-5, n=6-10, Continuous capture, Custom
• Calculate the capability or control-limit targets you want preconfigured (sigma level, Cpk target per characteristic).
• Summarize the alarm and escalation path when control limits are exceeded (operator response, QC engineer, maintenance, supplier notification).
• Prioritize which lines or products receive SPC rollout first based on defect history, PPM trends, or OEM risk scoring. Options: Highest PPM, OEM critical parts, Pilot line, Other

Configure Nonconformance and Corrective Action Workflows

• Allocate the nonconformance categories and default dispositions for each type (incoming, in-process, final, customer return, supplier nonconformance). Options: Incoming, In-process, Final, Customer return, Supplier nonconformance
• Schedule SLA targets for containment and root cause activities per priority (for example 24-hour containment, 30-day corrective action).
• Plan the NCR form fields and mandatory attachments (photos, measurement data, containment evidence) required to support closure and audit trails.
• Which roles within your organization will approve dispositions and verify containment on nonconformances?
• How will nonconformance dispositions trigger inventory or ERP actions (hold codes, scrap, return-to-supplier authorizations)?

Facilitate 8D Corrective Actions and Verification

• Allocate which functions will participate in 8D teams for problem-solving (engineering, production, purchasing, supplier quality, metrology).
• Schedule whether you require standardized 8D templates that align to OEM problem-report expectations. Options: Yes, No
• Plan the typical verification artifacts you use to demonstrate corrective action effectiveness (run-at-rate data, reduced SPC alarm counts, lower returned-part PPM).
• Who will verify supplier corrective actions and record supplier containment evidence in the system?
• Indicate the maximum allowable time between NCR creation and entry of initial containment actions into the 8D workflow. Options: Within 24 hours, Within 72 hours, Within 7 days

Develop Operator Work Instructions and Visual Controls

• Name the operations and stations that need new or revised operator work instructions and visual controls (assembly, press, machining, test).
• Indicate whether instructions must include step-by-step visuals with photos and torque values or if text-only is acceptable. Options: Visual with photos and values, Text-only, Combination
• State who will own revision control and release approval for operator instructions on the shop floor.
• Outline the languages and shift-specific variants required for work instructions and visual controls.
• Supply the validation method you will use to confirm operators follow instructions (live audits, tablet confirmation, sign-off sheets, sensor proof). Options: Live audits, Tablet confirmation, Sign-off sheets, Sensor proof

Deliver Operator and Inspector Training Sessions

• Select the number of operators and inspectors requiring training per plant and per shift. Options: <25, 25-100, 101-500, >500
• Choose preferred training formats (classroom, shop-floor practical, blended e-learning with assessments) for each role. Options: Classroom, Shop-floor practical, Blended e-learning with assessments, Other
• Give the expected training hours per role for initial qualification (operator, inspector, internal auditor). Options: 1-4 hours, 4-8 hours, 8-16 hours, Custom
• Assign whether training records must be exported to your HR or LMS system for employee qualification tracking. Options: Yes, No
• Provide the plant-level training coordinator contact or role who will schedule sessions and confirm shift windows.

Perform Pre-Certification Internal Audit

• Identify which IATF 16949 clauses or recent OEM audit findings must be prioritized during the internal audit.
• State the internal-audit sample size and scope you expect (number of processes, number of sites, audit days).
• What acceptance criteria will define 'audit ready' for registrar stage 2 (for example zero major nonconformities, maximum allowed minor count)? Options: Define acceptance criteria now, I need help defining criteria
• Who will act as the auditee contact and provide objective evidence such as control plans, PPAP packages, MSA reports, and FMEA during the internal audit?
• Are you requesting an action-tracking register included with the audit report that maps nonconformities to owners and target close dates? Options: Yes, No

• Master Services Agreement (MSA)
• Statement of Work (SOW)
• Order Form / Subscription Agreement
• Service Level Agreement (SLA)
• Acceptance Criteria & Sign-off Checklist
• Training Agreement
• Change Order Agreement
• Payment Schedule & Invoice Terms
• Confidentiality Agreement (NDA)
• Data Processing Agreement (DPA) — conditional

• Close all internal-audit nonconformities
• Document corrective-action effectiveness verification
• Issue final internal-audit report
• Obtain management-review sign-off to proceed to certification
• Publish controlled QMS documents and revisions
• Confirm training and competency records for all revised processes
• Complete and approve MSA and SPC deliverables
• Lock production configuration baseline and integration endpoints
• Assemble certification evidence pack for registrar
• Confirm registrar audit windows and named site owners
• Obtain formal client acceptance and billing milestone authorization

• Surveillance Readiness Check
• First Measurement Review
• Surveillance Audit Preparation
• Quarterly Sustainment Review

• Confirm shared channel SLAs and update escalation contacts if any roles have changed.
• Create remediation tasks for each failing metric with explicit owners and due dates.
• Schedule targeted refresher training for roles linked to the primary failure modes identified.
• Internal audit closure and evidence package
• Complete, organized evidence package ready for the surveillance auditor.
• All open internal-audit nonconformities either closed with evidence or on a short remediation track with dates.
• Confirmation that the targeted percent of processes with SPC in control meets the Implementation Scope expectation or has corrective actions in place.
• Produce and share the final pre-audit evidence binder and access links to data streams required by auditors.
• Close any critical internal-audit nonconformities or document containment and corrective action timelines.
• Run any outstanding MSA studies and publish results for auditor review.
• Quarterly trend review
• Confirm whether PPM defect rate and digital inspection capture rate are on a path to meet Implementation Scope targets.
• Agree top sustainment priorities and a schedule for their delivery and measurement.
• Ensure the issues and enhancements backlog is prioritized with clear owners and expected completion windows.
• Publish the quarterly sustainment report with trend charts and the prioritized backlog for the next quarter.
• Create targeted improvement tasks for SPC instability areas with owners and milestones.
• Reconfirm acceptance criteria and owners
• All measurable acceptance criteria from Implementation Scope have a confirmed owner and target state documented.
• High-priority blockers are identified with remediation actions and target completion dates.
• Deployment configuration and data access required for surveillance activities are validated.
• Publish a validated readiness checklist with owners and due dates for each item identified in the meeting.
• Resolve critical data access or integration failures before the next measurement review.
• If incumbent system existed, produce a one-page archive/migration report confirming its decommission or read-only status.
• Present first-cycle outcome data vs Implementation Scope targets
• Decision record of which metrics meet targets from Implementation Scope and which require remediation.
• A prioritized remediation plan with explicit actions, owners, and dates for each failing metric.
• Confirm the date for the next measurement checkpoint to validate remediation effectiveness.
• Publish the measurement report that compares PPM defect rate and open nonconformities to Implementation Scope targets.
• SPC monitoring and control stability review
• SPC alert and exception review
• Deployment and data access validation
• Root-cause diagnosis for gaps
• MSA and critical measurement readiness
• Early adoption and usage signals
• Open issues and enhancement backlog
• Agree corrective actions, owners, and dates
• Shared channel and escalation health
• Training records and auditor schedule
• Open issues and blockers with owners
• Training and adoption adjustments
• Immediate remediation actions
• Quarter priorities and next steps
• Finalize pre-audit checklist and close remaining items
• Incumbent system wind-down check (if applicable)