Integrated Management Systems

R. Dan Reid, Gregory Gruska, Chad Kymal

Description

Updated to the latest standard changes including ISO 9001:2015, ISO 14001:2015, and ISO 45001.
Includes guidance on integrating Corporate Responsibility and Sustainability.
Organizations today are implementing stand-alone systems for their Quality Management Systems (ISO 9001, ISO/TS 16949, or AS9100), Environmental Management System (ISO 14001), Occupational Health & Safety (ISO 18001), and Food Safety Management Systems (FSSC 22000). Stand-alone systems refer to the use of isolated document management structures resulting in the duplication of processes within one site for each of the management standards-QMS, EMS, OHSAS, and FSMS. In other words, the stand-alone systems duplicate training processes, document control, and internal audit processes for each standard within the company. While the confusion and lack of efficiency resulting from this decision may not be readily apparent to the uninitiated, this book will show the reader that there is a tremendous loss of value associated with stand-alone management systems within an organization.
This book expands the understanding of an integrated management system (IMS) globally. It not only saves money, but more importantly it contributes to the maintenance and efficiency of business processes and conformance standards such as ISO 9001, AS9100, ISO/TS 16949, ISO 14001, OHSAS 18001 / ISO 45001, FSSC 22000, or other GFSI
Standards.

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Gestion et management
• ISO 14000
• ISO 9000
• Economics
• Formation supérieure aux métiers du son
• OHSAS
• Leadership
• EMS
• QMS
• IMS
• ISO 14001
• ISO 9001

Informations

• Publié par: ASQ Quality Press
• Date de parution: 23 mars 2015
• Nombre de lectures: 0
• EAN13: 9781953079756
• Langue: English
• Poids de l'ouvrage: 4 Mo

Extrait

Integrated Management Systems

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Integrated Management Systems

QMS, EMS, OHSMS, FSMS including Aerospace, Service, Semiconductor/ Electronics, Automotive, and Food

Updated to the latest standard changes including ISO 9001:2015, ISO 14001:2015, and ISO 45001:2016 Includes guidance on integrating Corporate Responsibility and Sustainability

Chad Kymal, Gregory Gruska, and R. Dan Reid

ASQ Quality Press Milwaukee, Wisconsin

American Society for Quality, Quality Press, Milwaukee, WI 53203 © 2015 by ASQ. All rights reserved. Published 2015. Printed in the United States of America.

20 19 18 17 16 15 5 4 3 2 1

Library of Congress Cataloging-in-Publication Data

Kymal, Chad. Integrated management systems: QMS, EMS, OHSMS, FSMS including aerospace, service, semiconductor/elecrtronics, automotive, and food / by Chad Kymal, Gregory Gruska, and R. Dan Reid.  pages cm ISBN 978-0-87389-894-2 (hardcover: alk. paper) 1. Quality control—Management. 2. Quality control—Standards. 3. Management information systems. I. Gruska, Gregory F., 1943- II. Reid, R. Dan (Robert Dan), 1949- III. Title. TS156.K96 2014 658.5’620218—dc23  2014040874

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Printed on acid-free paper

Contents

List of Figures and Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About the Authors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapters

1

2

3

What are Integrated Management Systems, including PAS 99? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated Risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAS 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integration vs. Standardization—Why We Need Both . . . . . . . Integrated Processes—Enterprise . . . . . . . . . . . . . . . . . . . . . . . . . . . Standardization of Management Systems . . . . . . . . . . . . . . . . . . . . Integrated Audits—Enterprise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IntegratingProcessesbetweenQMS,EMS,OHSMS, and FSMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integration Within One Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Designing the Manual (Apex Document)—Level I . . . . . . . . . . . . Process Approach, the Key to Integration—Level II . . . . . . . . . . . Developing Integrated Management Systems Procedures—  Level II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Developing Integrated Management Systems Work  Instructions—Level III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

v

i

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xvii

1 1 1 5 6 7 8

13 14 15 18 19

25 25 27 29

35

39

vi

Contents

4

5

6

Developing Integrated Management Systems  Forms/Checklists—Level IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enterprise Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix—Business Planning Process . . . . . . . . . . . . . . . . . . . . . .

Integrated Risk Management and Enterprise Risk . . . . . . . . . . Using the Same Risk Methodology Process . . . . . . . . . . . . . . . . . . Identifying Q, E, and HS Risk in a Manufacturing Process . . . . . Identifying Q, E, and HS Risk in a Process in the Process Map . . Understanding Severity, Occurrence, and Detection . . . . . . . . . . . Security, Occurrence, and Detection Ratings . . . . . . . . . . . . . . . . . FMEA and HACCP Methodologies . . . . . . . . . . . . . . . . . . . . . . . . . Enterprise Risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ConductingIntegratedAudits............................ Integrated Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated Audit Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enterprise Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrective Action Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audit Duration and Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auditor Qualiîcation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Analysis and Continual Improvement . . . . . . . . . . .

HowanIntegratedandStandardizedManagementSystem Performs For Maximum Eectiveness. . . . . . . . . . . . . . . . . . . . . Process Maps and Process Deînitions. . . . . . . . . . . . . . . . . . . . . . . Enterprise Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Site Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Developing the Performance Management System—  Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manufacturing Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . Risk and Change Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 40 41 42

51 51 53 55 55 55 56 59

61 61 65 71 73 74 75 76

79 79 81 81

81 90 91 93

7

8

9

10

11

12

13

14

Contentsvii

IntegrationwithGFSIStandardsintheFoodIndustry...... Documentation Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process Improvements from the Implementation . . . . . . . . . . . . . Process Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Developing a New Product Development Phase Gate Process . . Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Third-party Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integration in an Automotive Organization . . . . . . . . . . . . . . . .

Integration in a Service Environment—a Case Study . . . . . . .

Integration in an Aerospace Organization—a Case Study . . .

Integration in a Semiconductor Organization— a Case Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SoftwareEnabledIntegratedManagementSystem for the Enterprise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated Enterprise Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lessons Learned from IMS Implementations . . . . . . . . . . . . . . Top Management Mindset and Involvement in  the Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scoping the Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Improvement versus Documentation . . . . . . . . . . . . . . . . . . . . . . . Summary of the Five Implementations . . . . . . . . . . . . . . . . . . . . . .

Integrating QMS, EMS, OHSMS, and FSMS . . . . . . . . . . . . . . .

Appendix A: Integrating and Standardizing QMS, EMS, and OHSMS Management Systems—An Executive Management Primer. . . . . . . . . . . . . . . .

Appendix B: Implementing Corporate Sustainability and Responsibility (CSR). . .

Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bibliography. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 100 102 104 106 106 107

109

121

127

135

143 148 152

153

154 156 157 162

163

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177

185

189

191

Figure 0.1

Figure 1.1 Table 1.1 Figure 1.2 Table 1.2 Table 1.3 Table 1.4

Figure 2.1 Table 2.1 Table 2.2 Table 2.3 Table 2.4 Table 2.5 Table 2.6

Figures and Tables

No integration or standardization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No integration or standardization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process integration matrix example (single site) . . . . . . . . . . . . . . . . . . Three pillars of an integrated management system . . . . . . . . . . . . . . . Integrated risk matrix example (single site) . . . . . . . . . . . . . . . . . . . . . . Integrated audit process example (single site) . . . . . . . . . . . . . . . . . . . . Single site process integration risk matrix . . . . . . . . . . . . . . . . . . . . . . .

Stand-alone systems in an enterprise vs. enterprise integration . . . . . Enterprise process score . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standardized enterprise risk matrix example . . . . . . . . . . . . . . . . . . . . Standardized enterprise audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enterprise process score . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standardized enterprise risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standardized enterprise audit of three sites . . . . . . . . . . . . . . . . . . . . . .

Figure 3.1 No integration or standardization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3.2 Stand-alone system (one site) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3.3 Process map example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3.1 Management review topics matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3.2 Process integration matrix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3.4 BMS control plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3.5 Controls–risk evaluation relationship . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3A.1 Operational review meeting minimum agenda requirements . . . . . . Figure 3A.1 Business planning and review ow chart. . . . . . . . . . . . . . . . . . . . . . . . Figure 3A.2 Strategic plan timetable example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3A.3 Strategic plan table of contents example. . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4.1 Figure 4.2

Managing risk in EMS and OHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

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xiv

2 3 4 6 7 9

14 15 17 18 20 21 21

26 27 30 35 37 38 39 48 49 50 50

52 52