How to Prepare for a VDA 6.3 Process Audit: A Tier 1 Supplier Checklist

The VDA 6.3 standard is one of the most rigorous auditing tools in the automotive industry, particularly for suppliers working with German OEMs. This guide provides a detailed checklist to ensure your facility is prepared for every phase of a VDA 6.3 Process Audit, minimizing risk and maximizing your score.

Understanding the VDA 6.3 Structure

Unlike simpler audits, VDA 6.3 evaluates the entire product life cycle through seven specific modules (P2 to P7). Preparing means focusing on process effectiveness, not just compliance documents.

The 7 Modules (P2 – P7)

• Project Management: Planning, resource allocation, and project control for new products.
• Transfer of Requirements: Ensuring all customer requirements are correctly flowed down and understood.
• Product and Process Design: Validation and control of both the product design and manufacturing process.
• Supplier Management: Evaluation and control of your sub-suppliers.
• Process Analysis/Manufacturing: The heart of the audit, evaluating the series production process.
• Customer Care, Customer Satisfaction, Service: Post-delivery performance and feedback loop.

Phase 1: Pre-Audit Preparation (The Essentials)

• Auditor Qualification: Confirm the auditor is certified as a “VDA 6.3 Auditor” by VDA QMC.
• Scoping Confirmation: Clearly define the scope of the audit (which processes, which products) with the customer.
• Process Mapping (Turtle Diagram): Ensure current, accessible process maps are available for all P-elements in scope, especially P6 (Manufacturing).
• Risk Analysis Documentation: Have documented evidence of Failure Mode and Effects Analysis (FMEA) for both Design (DFMEA) and Process (PFMEA).
• Performance Data: Compile data on internal and external PPM rates, scrap rates, and customer complaints for the last 12 months.

Phase 2: The Critical Manufacturing Module (P6)

P6 typically carries the highest weight. Be ready to demonstrate control over these areas:

• Personnel & Qualification: Records demonstrating training, authorization, and ongoing competence for all operators.
• Resources & Equipment: Calibration records, preventative maintenance schedules, and evidence of capability studies (e.g., MSA).
• Work Instructions: Instructions must be visible, understandable, and strictly adhered to by operators on the shop floor.
• Material Handling: Clear identification, traceability, and segregation of incoming material, in-process parts, and non-conforming materials.
• Measurement & Inspection: Proof that all required process and product inspections are being performed at the correct frequency and that reaction plans are in place for non-conformances.

Phase 3: Corrective Action & Re-Evaluation

A VDA 6.3 audit concludes with a rating. Any non-conformance requires immediate, documented action.

• Action Plan Timeline: Assign ownership and set strict deadlines for corrective action completion using the 8D methodology.
• Effectiveness Review: Do not just fix the symptom. Prove that the corrective actions are robust and have permanently eliminated the root cause.
• Re-Audit Planning: Understand the requirements for a follow-up audit to verify the effectiveness of your implemented actions.

PTI is dedicated to helping Tier 1 suppliers navigate the complexity of global quality standards like VDA 6.3, IATF 16949, and AIAG.