Today we will review the top IATF 16949 Audit Findings of 2025 in the automotive sector. This will also give you guideline to prevent them before your certification/recertification or surveillance audit.
One of the top major nonconformities the auditors came across in 2025 was weak problem-solving process. Root cause analysis carried on symptoms rather than true problem, causing repeat quality and delivery issues. FMEAs and control plans not considered as live documents and were not updated as corrective actions were devised. Missed regular review at specified intervals. Lessons learned not standardized and not shared across the organization and sites.
All this leads to 3rd party sort activities, and many organizations spend over $500,000 every year on third-party services. Further customer satisfaction decreases with weak problem-solving process. Below actions will help mitigate the issues from arising again.
After weak problem analysis the second major that goes hand in hand with it was ineffective Corrective action.
Poor corrective action process weakens the Quality Management System. Simultaneously a poor-Quality Management System leads to poor business performance. It leads to high repeat complaints and jeopardizes certification process.
The most common finding globally reported in 2025 was gap in the control plan process and poor MSA system. Control plans were not aligned with PFMEA. Controls for processes were not in place or were ineffective. Reaction plan column was missing. Process changes were not reflected on CP and operator weak knowledge on the parameters set on the CP. Along with CP issues, Outdated GR&R studies and out of calibrated equipment were found. Process capability data was missing.
The most common finding under this umbrella was missing documented information on contingency plan and were not tested. Poor backup plans for measuring devices, machines, operators, utilities and suppliers. Poor communication plans for emergencies. Many organizations fail to “prove” their contingency plans are effective. Further poor supplier control, and poor monitoring of supplier performance. Escalation rules not in place for poor performance. CSRs not communicated to suppliers and missing supplier development program.
How to Avoid These Findings and Prepare for Your Next Audit
FAQ Section
Q1: Why do organizations fail IATF 16949 audits?
A1: Organizations fail IATF audits as they consider IATF as a paper requirement not as a strategic tool that aligns their processes and organizations scope together.
Q2: How can I reduce audit findings in my IATF system?
A2: The best approach is strengthening your QMS, follow the standard and have strong controls in place to eliminate repeat issues.
Q3: What are the new focus areas for IATF audits in 2026?
A3: The new revision will come in Sep 2026. Signup for our newsletter to keep track of the new revision.
Q4: What is the cost of IATF consulting in Canada?
A4: Kadmar Consultants provides budget friendly prices that gives significant ROI.
Kadmar Consultants specialize in:
Our consultants have helped companies across Canada reduce:
Audit findings, Cost of poor quality, Customer complaints, Production downtime, Supplier issue
We’ll review your current challenges and provide a customized roadmap based on your organizations need.
Author: Asma Rashid
Kadmar Consultants helps Canada & America manufacturers achieve ISO 9001 and IATF 16949 certification through consulting, training & audit.
Want to Pass ISO 9001 & IATF 16949 Audit with zero stress? Manufacturing and automotive organizations in Canada face immense pressure when getting prepared for the audit. Many organizations focuses on achieving zero major nonconformance and passing the audit to maintain customer business and trust is correct but it overshadows the bigger picture — Organizations that implement the standard correctly and embed Quality Management System into their operations attract new business and sustain current clients.
No one wants the audit to be stressful and the solution to this problem is organizations have their system and team prepared 24/7 as a natural part of the operations.
Kadmar wants to help all the organizations across Canada to build a robust quality culture and mindset.
Customer satisfaction is the key to Pass ISO 9001:2015 & IATF 16949 Audit. Organizations can achieve customer satisfaction in no better way other than to eliminate quality repeat issues and expedite deliveries. Organization focusing on unfolding the true problem and eliminating the root cause are the real winners. A customer complaint is a representation of dissatisfaction towards the Quality Management System.
Kadmar Provides a structured, Integrated Complaint Handling Process that focuses on analyzing the problem before uncovering the root cause and developing corrective action.
The manufacturing area serves as the hub of any organization because it makes customer product directly and requires strong process controls at required stages of production. Organizations working on standardize process are capable of robust process that meets customer’s demand.
ISO 9001 and IATF 16949 both focuses on risk-based approach towards defining processes and anticipating risk involved in each phase and actions to mitigate it. Process Map helps organization standardize the processes and creates interlink between different processes to improvise overall organizations performance.
Internal Audit is more than a formal and mandatory requirement. It is a health check tool to evaluate Quality Management System gap. Organization should plan Internal Audits in accordance with the standard requirement to take full advantage of the tool. It is a real gap assessment alongside with Management Review.
Management Review validates if organization is continually achieving its goals and is aligned with the organizations scope. Management Review validates the effectiveness of the organization’s performance. All the processes revolve in a Plan Do Check Act cycle circle and Management Review is the key evaluator of it. Management review should be conducted at least once a year and drive changes throughout the organization to help it sustain in the competitive and unpredictable era. Quality is no longer the responsibility of the Quality Manager alone. It is the responsibility of organizations leader to reinstate quality culture where everyone is responsible to do the thing right first time every time and take ownership of their processes.
Employees are the most important and valuable asset of your organization. Workforce drives the success of the organization through their hard work and determination. Without employee empowerment, the Quality Management System will fail. Strong organizations are aware of the employee role and their effect on the key deliverables and working in growing and training their employees in the area of quality, defect prevention, and QMS principles.
Kadmar Consultants builds partnership with its clients as their business success is tied to our success. Our expert work diligently with all the clients ensuring all key deliverables are achieved. We don’t get organizations prepared only for paper certification we embed the guiding principles into the system, so they have a robust system, and Canada becomes quality hub for the entire world. Let’s embrace a culture where audit is not considered a stress, the standard is not a paper document, certification is not just a wall item, quality and delivery are not isolated process, leadership engagement does not stop at Mid management, saving is not just cutting expenses. Quality is a commitment of transparency and honesty and a guiding principle for the organizations.
Kadmar Consultants provides fast track certification services that helps organization to continue focusing on their business while we develop their Quality Management System. We have experts that understands your organizations needs and requirements and aligns with customer requirements. Our expertise include:
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