1. | 1
VDA 6.3 - Update Progress
- Status Report by the Working Group -
2. | 2
VDA 6.3 Process Audit
Revision 2016
1998 2010
2016
VDA
Quality Management
In the Automobile Industry
Process audit
6
Product creation process / full production
Services creation process / providing the services
Part 3
Verband der
Automobilindustrie
VDA
Quality Management
In the Automobile Industry
Process audit
6
Product creation process / full production
Services creation process / providing the services
Part 3
Verband der
Automobilindustri
e
VDA
Quality Management
In the Automobile Industry
Process audit
6
Product creation process / full production
Services creation process / providing the services
Part 3
Verband der
Automobilindustri
e
2016
3. | 3
Starting point:
The established VDA 6.3 audit standard (issued in 1998) was
revised completely in 2010 by the VDA working group.
The objective was to reform the process audit, make it more precise and
adapt it to new requirements. Business processes in the supply chain and in
product creation were analysed to ensure weaknesses in the work-sequence
processes were detected. Corrective measures were defined which then
enabled potential improvements to be made.
At the meeting on 15th April, 2015, of the "Quality management in the
automobile industry" (QMA) committee it was decided that the
VDA 6.3 publication should be revised
4. | 4
Main Tasks:
Secondary
Objectives:
- Updating, revision and if necessary, supplementing VDA 6.3
- Integration of the previous practical experience (SIs, FAQs,
Forum)
- Tightening, simplifying and summarising the questionnaire
catalogue and calculation of the result.
- Taking account of new subjects like new technologies,
digitalisation and Industry 4.0
- New definition of the procedure for auditing service-processes
- Unification and clarification of terms and definitions in the English
translation
Work Orders QMA ( Quality Management Board)
5. | 5
Group leader: Mr. C. Böttger. Group mentor: Mr. A. Schaarschmidt
(both from Volkswagen AG)
The life of the working group:
The up-dating and revision was to be completed in less than one year
(monthly meetings)
The Working Group Team
Vehicle makers:
Adam Opel AG
Audi AG
BMW AG
Daimler AG
Ford-Werke GmbH
MAN Truck & Bus GmbH
Porsche GmbH
Volkswagen AG
Suppliers:
Benteler Automotive GmbH
Borg Warner
Continental AG
Haman Becker
Knorr-Bremse SfN GmbH
Magna International Europe AG
Otto Fuchs
Robert Bosch GmbH
Rollax
Schaeffler AG
ZF AG
Support:
Technische Universität Berlin
VDA QMC
QMA member
6. | 6
VDA 6.3 Process Audit - Growth in Auditor Numbers
Status: 31.12.2015
The growth in certified VDA 6.3 process auditors - worldwide -
(cumulative)
7. | 7
#NP#_fdBdT8IwFAbgv7L0SiODdl+w3W2sREABGQMTa8jsOtMo67IVEQn/3TO8MN540Zv3PH1Pck6IcxQ8ndBUHFFw Qnwcow ARdO6gdfa+F202ztsIE4w6iP9B5/MzRDz/vw GxXpxpcUUct+9h7BEHY3wDffia9VBbk cv2ZwaUytK4l7xWjSq0MS8Ky YUZlgdR5qKG/S8t+gULdRD1QslSwyy /bHY33tS+nZLHOfVJOBulG291lxJnNA NSVCCGAWNpI+qGsS /XwwPsMhaL5k2rirF1HBpe1zYsTCBOjrtKNXK/g4GqdZ29bgF sAWyX4kM2UpXdqtKfUF39rCfJPE3sS ZqMl87yYRKtV 0OX0sk qWYDRFzKIhn4U+5FpE2qZDv X7ZhhRbEbYHhDH8i14cNtv_#NP#
...
Input VDA Forum
Input VDA QMA
Input Kick-Off
Work package
Qualification
Evaluation
Questions
The extent of revision
work to be carried out on VDA 6.3
Themes agreed by the VDA-6.3 working group
at the preliminary meeting of 27 May 2015
8. | 8
Potential Analysis (P1)
P2 / P3
P2 – P4
P5– P7
Innovation Phase Series Production
Innovation
release for
series
development
ML0
Management of
contractual
requirements
ML1
Determination
of the supply
chain and
extent of
contracts
ML2
Release of
technical
specifications
ML3
Completion of
production
planning
ML4
Necessary series
tools and
available
systems
ML5
Product release
and process
release*
ML6
Completion of
project, passing
on of
responsibilitiies
to series,
starting
requalification
ML7
Area of application of a process audit
Maturity Levels (ML)
VDA Maturity Level Assurance
9. | 9
Revision of the audit questionnaire
The previous structure is to be retained
• P2 Project management
• P3 Planning the product & process development
• P4 Carrying out the product & process development
• P5 Supplier management
• P6 Processes / production
• P7 Customer service
• P6 sub-elements The turtle is retained
- Input
- Process control
- Personnel resources
- Material resources
- Effectiveness, efficiency
- Output
Premises:
Concentrate and
consolidate questions
by themes
Ensure "auditability“ -
it must be possible to
carry out checks and
assessments on site
Restrict operations
to process-specific
points
Use uniform terms
and expressions
10. | 10
Revision of questionnaire catalogue
2010: 60 Questions 2016 : 57 Questions
New
11. | 11
P4: Implementation of the product and process development
Now 7 questions, previously 9 questions:
Revision of questionaire catalogue
2010
P 4.1 Implementation of corrective actions
regarding product/process FMEA
P 4.2 Implementation plans of product and
process development
P 4.8 Implementation of planned
sourcing activities
New
Summarized in:
P 4.1 Are the actions which were defined in
the product and process development
phases implemented?
incl. FMEA-actions and
sourcing activities
12. | 12
P6.2: Work content/process flow (are all production processes
controlled)
P6.4: What means are used to implement the process? (material
resources)
Revision of questionaire catalogue
2010
6.2.3 Can the product-specific requirements
from the customer be met with the
manufacturing equipment?
New
Shifted to:
6.4.1 Can the product-specific requirements
from the customer be met with the
manufacturing equipment?
13. | 13
P7: Customer care / customer satisfaction / service
Now 5 questions, previously 6 questions:
Revision of questionaire catalogue
2010
7.4 Failure analysis / corrective actions
7.5 Field Failures Analysis
New:
Summerized:
7.4 If there are deviations from quality
requirements, are failure analyses carried out
and corrective actions implemented
effectively?
incl.
…claims in the Field
The Field failure analysis has to be carried
out based on customers demand.
14. | 14
The questionnaire catalogue(Chapter 8.8) is now revised after the first VDA 6.3
edition from 1998
Service processes
D1 Planning
D2 Outside services
D3 Service process
D4 Customer satisfaction/
customer support
Process elements service
D2 Project management
D3 Planning service development
D4 Implementaion service /service development
D5 Supplier management
D6 Providing the service
6.1… Process input
…6.6 Process result
D7 Customer care / customer satisfaction / service
Old New
Revision VDA 6.3 Process Audit Service
15. | 15
Simplifying the assessment system, part 1
• Deletion of the assessment system using
the generic launch-pad
• No downgrading based on the generic
launch-pad
• Experience has shown that, in practice,
the system has little influence on the
result of the assessment. In addition,
allocation of questions to the individual
elements of the generic launch-pad is
not always clear.
PV :
Process
responsibility
ZI :
Target
orientation
KO:
Communication
RI:
Risk
orientation
Generic launch-pad
Levels of achievement
based on the
generic launch-pad
16. | 16
The "question weighting" work package
• The problem:
The audit result is calculated taking 1/3 from each of P5/P6/P7
and this gives the individual questions very different weightings.
• The proposed solution:
Give each question the same weighting (i.e., scrap the 1/3 calculation).
Note: where several process stages are involved, the questions in P6
are weighted as an average over all the process stages
P5/P6/P7 audit (production):
No. of questions
0
5
10
15
20
25
30
P5 P6 P7
P5/P6/P7 audit (production):
Weighting of one question in %
0
1
2
3
4
5
6
P5 P6 P7
%
17. | 17
Simplifying the assessment system, part 2
• All questions have an equal weighting in
contributing to the result
• No figures are rounded up or down in
intermediate calculations
• In future, quality capability (A, B, C
grading) is calculated using the
following formula:
EG [%] =
Total sum of all points awarded
for the relevant questions
Total sum of all possible points
for the relevant questions
Old rule !
Total achievement grade EG
18. | 18
Further decisions regarding the assessment rules:
• The question assessment method to scheme 0,4,6,8,10 is retained
• The 80% and 90% achievement levels for gradings A, B and C are retained
• In practice downgrades because of process elements or sub-elements are rare:
- the 70% downgrading rule in C for sub-elements of P6 (Eu1- Eu7) was deleted
- the other downgrading rules for process elements and sub-elements are retained
• Weighting of questions:
- Each question is equally weighted to give the overall assessment.
Note: In order to achieve reliable comparability, at least 2/3 of the questions covering
process elements or sub-elements should be assessed.
• *questions are retained, including the downgrading rules
• The work involved in training is simplified by the simplified assessment
(hurdles and assessments are deleted - see above)
19. | 19
Potential analysis:
In terms of the assessment structure and
process sequence the potential analysis remains
unchanged from the 2010 revision level
Improvements made:
• New allocation of assessment questions from P2 to P7
• Explanations of the existing assessment rules
Clarification
of initial
situation
P1 Potenial analysis
Request /
evaluate the
supplier‘s
information
study
Compilation
of the
modular
questionnaire
Appoint the
audit team On-site visit Risk
assessment
Clarify
resources
necessary for
qualification
Nomination
20. | 20
Environ-
mental
Protection
•Compliance with
environmental
standards
•ISO 14001; EMAS
•Resource management
•Recycling
•Waste reduction
Social
Standards
• Human rights
• Safety and health
• ILO, UNGC, OECD
Charta
Work place
safety
• Hazard protection
• ASiG, BGV
• OHSAS 18001
New themes:
- sustainability
21. | 21
- Sustainability, social standards and
environmental protection extend beyond
the bounds of the quality process audit
(legal aspects, etc.)
- Certification and public authority monitoring
exist in this regard
- Note:
The existing questions in VDA 6.3 have not
been extended to cover these subjects, as
an obligation for the auditor to monitor them
might otherwise arise.
- The need for training in these subjects will
be taken into account in future in VDA QMC
training courses
Working group results on sustainability
Dodd-Frank-
Act. (USA)
Conflict resources
EMAS
Eco-Management and Audit Scheme
World Business Council for Sustainable
Development (WBCSD) (Weltwirtschaftsrat
für Nachhaltige Entwicklung)
ILO
International
Labour
Organization
www.ilo.org/global
UN Global
Compact
Human rights
Anti corruption
www.unglobalcomp
act.org/
OHSAS
Occupational
Health and
Safety
Assessment
Series
ISO 18001
ISO 14001 -
2015
Enviromental-
management
22. | 22
VDA 6.3 – Verbindung zu anderen Anforderungen
1410-LE10-TVDAF000-009
Assessment questions on matters of
sustainability, such as
compliance with social standards,
environmental protection and
the conservation of resources are not
included in the questionnaire
as there are separate monitoring systems,
legal regulations and
standards covering them.
However, If the auditor observes obvious
points that are contrary to the interests of the
company and/or have a lasting negative
influence on the product characteristics,
these should be documented and taken into
account in the assessment.
Written in the Yellow Print:
23. | 23
Auditors qualification
• Internal auditors
• Supply chain auditors
• External auditors in an
independent, third-party
organisation (external auditor
as an authorized
representative of the
organisation).
The auditors qualification is an important precondition to meet
the audit targets
The organisation needs a documented
process to evaluate the competence of
their own auditors for the following
aspects:
• Release of auditors
• Retension and Improvement of the
competenceund
• Witness audits
Mimimum requirements
settled in VDA 6.3:
24. | 24
1. Internal auditors (first party audit)
Technical knowledge
•Good knowledge of quality tools and methods (e.g., audit procedures, FMEAs,
8D method, PPF, SPC, FTA)
•Knowledge of relevant customer-specific requirements
•Knowledge of the relevant management system requirements (e.g., ISO/TS 16949,
DIN EN ISO 9001, VDA 6.1 )
•Product-specific and process-specific knowledge
Technical certification
•Successful participation (with examination pass) in a VDA 6.3 training course
Professional experience
At least 3 years' professional experience (from 2 years' professional experience
company training periods can be taken into account), preferably in manufacturing
companies in the automobile industry, with at least 1 year in quality management.
Finalised requirements for auditor qualification
25. | 25
2. Supplier auditors (second party audit)
Technical knowledge:
Very good knowledge of quality tools and methods (e.g., audit procedures, FMEAs,
8D method, PPF, SPC, FTA, SWOT, DOE)
Auditor qualification (leading discussions, conflict management, audit techniques)
Knowledge of relevant customer-specific requirements
Knowledge of relevant management system requirements (e.g., ISO/TS 16949,
DIN EN ISO 9001, VDA 6.1)
Product-specific and process-specific knowledge
Technical certification
Auditor qualification based on EN ISO 19011 (e.g., training in the principles of
VDA 6.3, 1st/2nd party auditor for DIN EN ISO 9001, ISO/TS 16949, or VDA 6.1)
Successful participation (with examination pass) in a VDA 6.3 training course held
by the VDA QMC or one of its licence partners.
Professional experience
At least 5 years' professional experience (as from 3 years' professional experience
company training periods can be taken into account), preferably in manufacturing
companies in the automobile industry, with at least 1 year in quality management.
26. | 26
3. External auditors in an independent, third-party organisation
(external auditor as an authorized representative of the organisation).
Technical knowledge; professional experience
Very good knowledge of quality tools and methods (e.g., audit procedures, FMEAs,
8D method, PPF, SPC, FTA, SWOT, DOE)
Auditor qualification (leading discussions, conflict management, audit technique)
Knowledge of relevant customer-specific requirements
Knowledge of relevant management system requirements (e.g., ISO/TS 16949,
DIN EN ISO 9001, VDA 6.1)
Product-specific and process-specific knowledge
Technical certification
Auditor qualification based on EN ISO 19011 (e.g., training in the principles of
VDA 6.3, 1st/2nd party auditor for DIN EN ISO 9001, ISO/TS 16949, or VDA 6.1)
Examination pass (certificate) as part of a VDA 6.3 training course held by the
VDA QMC or one of its licence partners
Professional experience
At least 5 years' professional experience (as from 3 years' professional experience
company training periods can be taken into account), preferably in manufacturing
companies in the automobile industry, with at least 1 year in quality management.
27. | 27
New training concept
Qualification
Process auditor VDA
6.3 Material products
• Application range
• Audit process
• Risk analyse
• Evaluation
• Auditor qualfication
• Questionarie P2-P7
• P1 Potential analyse
Qualification
Process auditor VDA
6.3 Service
• Application range
• Audit process
• Risk analyse
• Evaluation
• Auditor qualfication
• Questionnaire P2-P7
Examination Process
auditor
VDA 6.3
• Written exam 40
Questions (multiple
choice)
• Oral exam
• Case study
• Certificate
• Auditors card
28. | 28
Upgrade Trainings /Requalification VDA 6.3 2016
Upgrade Training
VDA 6.3 for certified
Process auditors
• Changes VDA 6.3
2016 to VDA 6.3
2010
• Test ( 20 questions
multiple Choise)
• 70% degree of
fullfillment
• New Certificate
• New Auditors card
Upgrade Training
VDA 6.3 for
Process auditors
• Changes VDA 6.3
2016 to VDA 6.3
2010
• Test ( 20 questions
multiple Choise)
• 60% degree of
fullfillment
• Qualifications
confirmation
Requalification
VDA 6.3 for certified
Process auditors
• Confirmation of the
Auditors practice
after 3 years
• Exchange of
expierience
• Extention of the
certificate
• Auditors card
33. | 33
Industry 4.0 in VDA 6.3?
Digitalisation should be covered in the
subjects regarding the individual questions
(e.g., traceability, change status, releases,
etc., …)
Background knowledge regarding data
transfer and data security will have to be
included in the future technical knowledge
and technical training of a process auditor
T.M.2016
Copyright
VDA QMC
Internet
of services
Internet
of things
The working group position:
At present, the development stage of
Industry 4.0 does not permit any
specific assessment questions to
be derived.
The questionnaire provides the possibility
of including specific subjects from
Industry 4.0 in the requirements
Using the
appropriate
audit standard
Intelligent factory
Back-up slide
