Why do you need this service?
A VDA 6.3 Process Audit assesses a process with a focus on risk, capability and the effectiveness of activities, from project preparation through series production to customer service. It helps identify gaps before they result in a customer complaint, a disrupted launch or an interruption to deliveries.
When is a process audit especially useful?
- before a new launch or a significant process change,
- as part of supplier qualification or development,
- after quality problems and recurring customer complaints,
- before an automotive customer audit,
- for periodic assessment of production process stability.
We select the scope to suit the objective and project maturity. The assessment may include P1 potential analysis and the relevant process elements P2–P7. We work to the agreed VDA 6.3 requirements without replacing a certification audit where one is required by the customer.
What is our role?
We prepare an audit plan based on the product, process flow, customer requirements and key risks. At the Gemba, we follow the evidence, ask process-focused questions and verify whether the methods described in the documentation actually control everyday work.
We conduct a VDA 6.3 Audit as a practical improvement tool. The report includes the assessment, supporting rationale, risks and a prioritised action plan. The audit team and scope are selected to match the competencies required. Where needed, we combine the assessment with Core Tools, supplier development or a quality management audit.
What does the organisation receive?
- assessment of the relevant P1–P7 elements,
- result classification and process evidence,
- a prioritised list of risks and non-conformities,
- an action plan with responsibilities,
- the option to verify effectiveness after implementation.
A handful of facts
0
process elements from P1 to P7
0
process result classes: A, B or C
0
risk-based action plan
Implementation support
We provide support based on the Kata process, which allows us to adapt our activities to the specifics of your organization, taking into account the jointly set goals. The Kata process consists of four key elements that enable effective implementation of assumptions.
We operate according to PDCA
P
PLAN
PLAN — process scope and risk
We agree the objective, product life-cycle stage, customer requirements and processes to be assessed. We review indicators, customer complaints, FMEA, the Control Plan, process flow, previous audit findings and open changes. We develop an agenda and a risk-focused sample.
- selection of elements P1–P7,
- a map of the process and its interfaces,
- analysis of quality and delivery data,
- selection of auditor competencies,
- assessment and reporting rules.
D
DO
DO — audit at the Gemba
We verify project and process planning, supplier management, production execution, resources, control of characteristics, logistics, data analysis and customer service. Each finding is based on observation, conversation and verifiable evidence.
- following the actual flow,
- consistency between FMEA, the Control Plan and work instructions,
- machine, process and measurement system capability,
- response to non-conformities and change management,
- competencies, resource maintenance and traceability.
C
CHECK
CHECK — assessment and gap analysis
We summarise the results for the elements assessed and identify the process classification as A, B or C in accordance with the assessment rules applied. The most important aspect, however, is understanding risk: which gaps could prevent launch, disrupt deliveries or lead to non-conformities at the customer.
- assessment of questions and process elements,
- verification of evidence and consistency of findings,
- prioritisation of risks,
- a closing meeting with owners,
- a report and recommended response deadlines.
A
ACT
ACT — actions and confirmation of effectiveness
We help translate the report into actions that remove causes and strengthen the system, rather than merely complete documents. We establish owners, deadlines and evidence of effectiveness. After implementation, we can review the actions or conduct a repeat audit.
- a plan for corrections and corrective actions,
- support with root cause analysis,
- updates to FMEA, standards and controls,
- monitoring of process KPIs,
- reassessment and rollout of good practices.
Want to learn more? Contact us!
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