VDA 6.3 Process Audit Thomas Junggeburth, VP German ...

1 VDA Process Audit Thomas Junggeburth, VP German Automotive Corp. About GAB Corporation Founded 2012 in Miami, Florida The owners are Germans, all worked in the German automotive industry for over 50 years Trainings, exams and services will be done by local trainers. We use highly qualified personnel only and continuously control the performance of our personnel. Of course all trainers are VDA and/or AIAG approved Our focus in USA are the German automotive Licensee of: & About VDA Process Audit 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 2nd fully revised edition, May 2010 VDA is the Process Audit standard in the German automotive industry It is used to assess and classify suppliers in the automotive supply chain (A,B and C) VDA Process Audit is worldwide applied for internal audits and PPA Process approval as well as supplier gap analysis Actual more then Process auditors are certified to VDA (exam passed)

2 VDA has links to other automotive standards required by customers VDA Process Audit focusing the product life cycle Product life Cycle Receive contract Issue contract SOP Quotation Process (contract review Implementation Product / Process development Serial production After sales Def. and Draft, Product & Process development Pre-select suppliers; Potential analysis OEM supplier Selection ; Potential analysis Project management (P2) Planning product & Process developement (P3) Realization of product & Process development (P4) Supplier management (P5) Production (P6) Customer support (P7) Potential analysis (P1) Process Audit questionnaire following the product life cycle per Process element: About VDA Process Audit 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 2nd fully revised edition, May 2010 VDA Process Audit new edition in 2016/2017 The work group to create a new edition of the VDA Process Audit standard has already Integration of current SI s and FAQ s Include lessons learned from VDA forum and trainings Improve consistency of used terms such as important , critical.)

3 Special characteristics Review and improve all questions to avoid repetition of requirements Introduce a section with terms and definitions Include additional requirements for sub-supplier management VDA Process Audit new edition in 2016/2017 The work group to create a new edition of the VDA Process Audit standard has already Revise/update requirements for project management, considering specific project management requirements and requirement of the Maturity Level Assurance for new party (MLA) Rules/recommendations for re- Audit (criteria) The so called generic scores will be deleted Downgrading rules will be simplified. VDA Process Audit new edition in 2016/2017 The work group to create a new edition of the VDA Process Audit standard has already Rules/recommendation to conduct Process audits for specific Process elements Balancing the weight of each question ( supplier management 5 questions, production 26 questions) Update of qualification requirements for auditors Basic qualification according to ISO 19011 will be required for auditors applying for VDA exam VDA Process Audit linkage to customer specific requirements Product life Cycle Receive contract Issue contract SOP Quotation Process (contract review Implementation Product / Process development Serial production After sales Def.)

4 And Draft, Product & Process development Pre-select suppliers; Potential analysis OEM supplier Selection ; Potential analysis Project management (P2) Planning product & Process development (P3) Realization of product & Process development (P4) Supplier management (P5) Production (P6) Customer support (P7) + Customer specific requirements VDA Process Audit linkage to German automotive standards Product life Cycle Receive contract Issue contract SOP Quotation Process (contract review Implementation Product / Process development Serial production After sales Def. and Draft, Product & Process development Pre-select suppliers; Potential analysis OEM supplier Selection ; Potential analysis German OEM s require VDA standards VDA Process Audit VDA 1 Documentation and Archiving VDA 2 Production Process and product approval (PPA) VDA 4 Product- and Process -FMEA VDA product Audit Maturity level assurance for new parts (MLA) Field failure analysis VDA Process Audit linkage to German automotive standards Product life Cycle Receive contract Issue contract SOP Quotation Process (contract review Implementation Product / Process development Serial production After sales Def.))

5 And Draft, Product & Process development Pre-select suppliers; Potential analysis OEM supplier Selection ; Potential analysis German OEM s require VDA standards VDA Process Audit VDA 1 Documentation and Archiving VDA 2 Production Process and product approval (PPA) VDA 4 Product- and Process -FMEA VDA product Audit Maturity level assurance for new parts (MLA) Field failure analysis linkage to other German automotive standards Maturity level assurance for new parts Product life Cycle Receive contract Issue contract SOP Quotation Process (contract review Implementation Product / Process development Serial production After sales Def. and Draft, Product & Process development Pre-select suppliers; Potential analysis OEM supplier Selection ; Potential analysis ML0 ML1 ML2 ML3 ML4 ML5 ML6 ML7 Innovation release for full production development Requirements management for the contract to be issued Specifying the supply chain and placing the order Release of technical specifications Completion of production planning Process and product approval Parts from production tools and production facilities are available Project completion, transfer of responsibilities to Production.)

6 Start requalification MLA assess the risk of each supplied component and classify them according to the risk in A, B or C components According to the risk assessment different types of project reviews were used linkage to other German automotive standards Maturity level assurance for new parts Product life Cycle Receive contract Issue contract SOP Quotation Process (contract review Implementation Product / Process development Serial production After sales Def. and Draft, Product & Process development Pre-select suppliers; Potential analysis OEM supplier Selection ; Potential analysis Self-assessment by the supplier : Information made available by electronic data transmission, dialogue with the customer if there is a risk of failing to meet the objective Self-assessment by the supplier.)

7 The supplier presents his assessment results and actions to the customer, active confirmation by the customer (problem-oriented toward customer or supplier) Round table assessment with all specialist functions involved and the supplier (problem-oriented toward customer or supplier) Medium maturity level risk Low maturity level risk C B DEGREE OF USE OF MATURITY LEVEL ASSURANCE Steuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Max MustermannSteuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Steuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Max MustermannSteuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Max MustermannSteuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Steuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Max MustermannSteuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Max MustermannSteuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Steuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Max MustermannSteuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Max MustermannSteuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Steuerger t4711xy-GmbHDXY-GmbHXY-GmbHW287 Max MustermannHigh maturity level risk A RISK Inter-disciplinary risk assessment component/supplier VDA Process Audit linkage to German automotive standards Product life Cycle

8 Receive contract Issue contract SOP Quotation Process (contract review Implementation Product / Process development Serial production After sales Def. and Draft, Product & Process development Pre-select suppliers; Potential analysis OEM supplier Selection ; Potential analysis German OEM s require VDA standards VDA Process Audit VDA 1 Documentation and Archiving VDA 2 Production Process and product approval (PPA) VDA 4 Product- and Process -FMEA VDA product Audit Maturity level assurance for new parts (MLA) Field failure analysis linkage to other German automotive standards Maturity level assurance for new parts Product life Cycle Receive contract Issue contract SOP Quotation Process (contract review Implementation Product / Process development Serial production After sales Def.))

9 And Draft, Product & Process development Pre-select suppliers; Potential analysis OEM supplier Selection ; Potential analysis Manufacturer Supplier Final customer/ Workshop Request for parts Invoice Warranty claim Process Customer complaint Claim Process Workshop Process Quality Process : Field failure analysis Part exchange Warranty/ claim request linkage to other German automotive standards Maturity level assurance for new parts Product life Cycle Receive contract Issue contract SOP Quotation Process (contract review Implementation Product / Process development Serial production After sales Def. and Draft, Product & Process development Pre-select suppliers; Potential analysis OEM supplier Selection ; Potential analysis Interfaces Interfaces Interfaces Part Analysis R O O T C A U S E A N A L Y S I S A N D F A I L U R E E L I M I N A T I O N P R O C E S S Standard tests N T F P R O C E S S System tests Jointly specified tests Data collection and evaluation Process study OK based on part analysis Tests under load 1.)

10 Failure - oriented 2. Jointly specified tests Customer complaint Indication of defect ? Yes 1. No 2. OK based on standard tests Interfaces Interfaces Interfaces Part Analysis R O O T C A U S E A N A L Y S I S A N D F A I L U R E E L I M I N A T I O N P R O C E S S Standard test N T F P R O C E S S System tests Jointly specified tests Data collection and evaluation Process study OK based on part analysis Test under load 1. Failure orientated 2. Jointly specified test Customer complaint Indication of defect ? Yes 1. No 2. OK based on standard tests FIELD FAILURE ANLYSIS Process Thank you for your attention. Thomas Junggeburth Vice President German Automotive Business Corporation Brickell Bayview 80 SW 8th Street, Suite 2000 Miami, FL 33130 USA Mail: URL VDA Process Audit GAB Europe GmbH (Germany) 25 Trainer/Consultants GAB-Corporation Asia (Thailand) 15 Trainer/Consultants GAB-Corporation (USA) 12 Trainer/Consultants Through our global presence it is possible for us to support you globally.