IATF 16949 in the commercial vehicle supply chain: what it means for your foundry supplier
IATF 16949 is the quality management standard for the automotive sector, and many commercial vehicle manufacturers and their tier-one suppliers require it of their own suppliers. For a grey or nodular iron foundry, holding this certification indicates that its processes are designed to prevent defects and control variation, and that an independent body audits the foundry. This guide explains what this means, what it entails on the shop floor, how the approval process for a new part works, and what evidence it is advisable to request.
1. What is IATF 16949?
It was published by the IATF (International Automotive Task Force), a group comprising automotive manufacturers and industry associations. It was introduced in 2016 to replace ISO/TS 16949 and is based on ISO 9001:2015, to which it adds specific automotive requirements: defect prevention, reduction of variation and waste in the supply chain, and compliance with each customer’s specific requirements.
It is certified by a certification body recognised by the IATF, with a three-year cycle and follow-up audits throughout that period.
2. Is it compulsory for a foundry supplier?
This certification is mandatory for any manufacturing plant that produces components for the automotive sector. As Funosa is a grey and nodular iron foundry that produces cast iron components for the automotive sector, it does indeed require this certification.
3. Why is this required for commercial vehicles?
The commercial vehicle sector is not part of the automotive sector; therefore, certification is not mandatory. However, some manufacturers of commercial vehicles may require their suppliers to be IATF-certified.
In our case, as part of our efforts to build confidence in our cast iron components for any sector related to the automotive industry, we do indeed have that confidence. In this context, what is valued is the ability to replicate the same result part after part and batch after batch, and to be able to react quickly when something goes off course. IATF 16949 formalises precisely that:
4. What does this involve at an iron foundry, and what evidence can you ask for?
The standard is a general one for the automotive industry. In a foundry, it is applied to processes that are specific to the sector, and each one leaves evidence that the supplier should be able to show you:
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Requisito
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Qué significa en un fundición
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evidencia que puedes pedir
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|---|---|---|
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APQP y PPAP |
Prior to the production run, it is demonstrated that the process (design, moulding, cores, casting, machining) meets the part’s specifications |
Approval dossier for a recent product |
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AMFE and control plan |
The risks associated with each phase are analysed and the methods for managing each one are defined |
AMFE and the control plan for a similar part |
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MSA and SPC |
The reliability of the measurement systems is verified and the stability of the process is monitored using data |
Capacity and measurement systems studies |
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Metallurgical control |
Composition, nodularity (only in ductile iron; in grey iron, this depends on the quality of iron required by the customer) and matrix structure are controlled and recorded for each casting |
Casting records and test results |
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Traceability |
Ability to identify which batch or parts are affected in the event of any deviation |
Traceability exercise: from an item to a batch and vice versa |
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Contingency plans |
A clear response to stoppages, breakdowns or power cuts |
Current contingency plan |
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Change management |
Changes to processes, designs or materials are assessed, validated and communicated to the customer |
Exchange procedure and a real-life example |
5. What is the step-by-step process for type-approval of a new component?
The process varies depending on the client. The faster and more reliable the transition from prototype to initial samples, the shorter the approval process. This is influenced by both the supplier’s industrialisation capabilities and the availability of in-house engineering and quality resources.
But the usual procedure in a foundry is as follows:
5.1 Application and feasibility study (also known as ‘Feasibility’)
The drawing is reviewed and an assessment is made as to whether the part can be manufactured to the required quality and cost.
5.2 Process and tooling design
The casting system, the cores and the pattern are defined, and the critical features are identified.
5.3 Prototypes
They enable the geometry to be validated and problems to be detected before investing in permanent tooling.
5.4 Initial samples
They are manufactured using standard processes and tooling and are thoroughly checked against the drawing.
5.5 Submission of the approval dossier (PPAP)
Gather the evidence relating to the process and the item, and have it approved by the client.
5.6 Series and follow-up
It is produced in accordance with the approved control plan, and its stability is monitored using data.
6. What does an IATF certificate guarantee (and what does it not guarantee)?
It ensures that there is a documented quality system, implemented and audited by an independent third party, and that it is compatible with your own quality system. This reduces risk and facilitates certification, as many requirements are already met.
It does not guarantee the quality of each item – as demonstrated by each type approval – nor does it replace audits of your own procurement system.
7. Scope: the most overlooked aspect of verification
An IATF certificate specifies a scope: the location and processes of your production plant. Two suppliers might say, ‘We are IATF 16949-certified’, yet be referring to different things. One might say:
- The scope may exclude the product design (but not the design of the manufacturing process). The standard only permits the product design to be excluded from the certificate.
- If a plant manufactures parts for the automotive sector and parts for other sectors (for example, the railway or agricultural sectors), the audit and IATF requirements apply to the plant’s entire management system, even if the end customer in the automotive sector only purchases one product.
- Outsourced processes fall within the scope of the certification, under the responsibility of FUNOSA, and the subcontractors must hold at least ISO 9001 certification.
Once the scope has been established, these checks complete the analysis:
7.1 Validity and issuer
A valid certificate issued by a body recognised by the IATF.
7.2 APQP and PPAP capabilities
Ask for examples of how a new reference is approved.
7.3 Traceability and containment
Ask how and how long it takes to cordon off an affected plot.
7.4 Client-specific requirements
They must be identified and kept under control.
FREQUENTLY ASKED QUESTIONS
8. FUNOSA and IATF 16949
FUNOSA is a grey and nodular iron foundry based in Barcelona. We have just renewed our IATF 16949 certification [September 2026].
We have our own in-house engineering and quality control teams, and we have enhanced our manufacturing capabilities with 3D printers to produce prototypes quickly, as well as a three-dimensional measuring arm in the Quality Control department to improve the quality of parts and models. We manufacture medium and large production runs, ranging from 120 grams to 120 kg.