1. VDA 6.3 - Update Progress - Status Report by the Working Group -

2. 2016 6 2016 6 6 VDA 6.3 Process Audit Revision 2016 1998 2010 VDA 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
1998
2010
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
Automobilindustrie
2016
2016

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. Work Orders QMA ( Quality Management Board)
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

5. The Working Group Team
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)
Vehicle makers:
Suppliers:
Support:
Adam Opel AG
Audi AG
BMW AG
Daimler AG
Ford-Werke GmbH
MAN Truck & Bus GmbH
Porsche GmbH
Volkswagen AG
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
Technische Universität Berlin
VDA QMC
QMA member

6. VDA 6.3 Process Audit - Growth in Auditor Numbers
The growth in certified VDA 6.3 process auditors - worldwide -
(cumulative)
Status:

7. work to be carried out on VDA 6.3
The extent of revision
work to be carried out on VDA 6.3
Input VDA Forum
Input VDA QMA
Input Kick-Off
Work package
Questions
Evaluation
Qualification
...
Themes agreed by the VDA-6.3 working group at the preliminary meeting of 27 May 2015
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8. Potential Analysis (P1)
Area of application of a process audit
Potential Analysis (P1)
P2 – P4
P2 / P3
P5– P7
Innovation Phase
Series Production
Maturity Levels (ML)
ML0
ML1
ML2
ML3
ML4
ML5
ML6
ML7
Innovation release for series development
Management of contractual requirements
Determination of the supply chain and extent of contracts
Release of technical specifications
Completion of production planning
Necessary series tools and available systems
Product release and process release*
Completion of project, passing on of responsibilitiies to series, starting requalification
VDA Maturity Level Assurance

9. Revision of the audit questionnaire
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
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

10. Revision of questionnaire catalogue
2010: 60 Questions : 57 Questions
New

11. Revision of questionaire catalogue
P4: Implementation of the product and process development Now 7 questions, previously 9 questions:
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. Revision of questionaire catalogue
P6.2: Work content/process flow (are all production processes controlled) P6.4: What means are used to implement the process? (material resources)
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. Revision of questionaire catalogue
P7: Customer care / customer satisfaction / service Now 5 questions, previously 6 questions:
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. Process elements service
Revision VDA 6.3 Process Audit Service
The questionnaire catalogue(Chapter 8.8) is now revised after the first VDA 6.3 edition from 1998
Old
New
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

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. 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

17. Total achievement grade EG
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:
Old rule !
Total achievement grade EG
Keine Rundungsregeln bei Zwischenergebnissen !
EG [%] =
Total sum of all points awarded for the relevant questions
Total sum of all possible points for the relevant questions

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. Potential analysis:
In terms of the assessment structure and process sequence the potential analysis remains unchanged from the 2010 revision level
Nomination
P1 Potenial analysis
Clarification of initial situation
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
Improvements made:
New allocation of assessment questions from P2 to P7
Explanations of the existing assessment rules

20. Environ- mental Protection
New themes:
- sustainability
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

21. Working group results on sustainability
OHSAS Occupational Health and Safety Assessment Series ISO 18001
ILO International Labour Organization
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
Dodd-Frank-Act. (USA)
Conflict resources
EMAS
Eco-Management and Audit Scheme
World Business Council for Sustainable Development (WBCSD) (Weltwirtschaftsrat für Nachhaltige Entwicklung)
UN Global Compact
Human rights
Anti corruption
ISO Enviromental-management

22. Written in the Yellow Print:
1410-LE10-TVDAF
VDA 6.3 – Verbindung zu anderen Anforderungen
Written in the Yellow Print:
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.

23. Auditors qualification
The auditors qualification is an important precondition to meet the audit targets
Mimimum requirements settled in VDA 6.3:
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
Internal auditors
Supply chain auditors
External auditors in an independent, third-party organisation (external auditor
as an authorized
representative of the
organisation).

24. Finalised requirements for auditor qualification
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.

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 (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. 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 (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. Examination Process auditor
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
Questionnaire P2-P7
Examination Process auditor
VDA 6.3
Written exam 40 Questions (multiple choice)
Oral exam
Case study
Certificate
Auditors card
New training concept

28. Upgrade Trainings /Requalification VDA 6.3 2016
Upgrade Training VDA 6.3 for certified Process auditors
Changes VDA to VDA
Test ( 20 questions multiple Choise)
70% degree of fullfillment
New Certificate
New Auditors card
Upgrade Training VDA 6.3 for
Process auditors
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

29. Internationalization of VDA 6
Internationalization of VDA 6.3 Process Auditors 2010 – 2016 TOP 10 countries
In this page you can see the number of auditors in the following countries ...
Germany, followed by China, Poland, Japan, US and the Czech Republic
But next countries, especially India and France are coming … also the Spanish speaking countries like Spain and Mexico.

30. Release timeline Release Yellow Print by VDA-QMA Feedback-phase
Release
Yellow Print by VDA-QMA
Feedback-phase
3 month
Red Print by
VDA-QMA
Start Update-training
>500
feedbacks
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31. Transitionperiod VDA 6.3 2016 - VDA 6.3 2016
Publication
Red Print
Jan 2017
Implementation
by 30th of June 2018
18 months

32. Thank you for your attention!

33. The working group position:
Back-up slide
Industry 4.0 in VDA 6.3?
Internet
of things
Internet
of services
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
Copyright
T.M.2016
VDA QMC
Intelligent factory
Fazit: Berücksichtigung von Software Entwicklung: Automotive-Spice Serie: Als „Komponente“ bzw. „Zulieferteil“ in den Prozessen.
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
Using the appropriate audit standard