VDA 6.3 Process Audit Template
A structured process audit based on the German automotive standard (Verband der Automobilindustrie). 28 audit questions across all process elements — from customer requirements through process capability and nonconformity management. The same rigor I applied auditing Volkswagen and BMW suppliers.
VDA 6.3 is the German automotive industry standard for process audits — stricter and more binary than IATF 16949. Where IATF asks "do you have a system?", VDA 6.3 asks "does the process actually work?" This template covers the core process elements with Yes/No questions that mirror the standard's binary approach.
How to use: For each question, answer YES or NO based on objective evidence. Any NO answer on a "potential risk" question (marked with ⚠) must trigger a corrective action request. Calculate the compliance percentage at the end.
VDA 6.3 vs. IATF 16949 — Key Differences
Focus: IATF = Quality System; VDA 6.3 = Process Audit
Scoring: IATF = scored 0-10; VDA 6.3 = binary YES/NO
Rigor: VDA 6.3 is stricter — one NO on a critical question can fail the entire audit
Origin: Developed by VDA (German Association of the Automotive Industry) for VW, BMW, Mercedes, Audi, Porsche supply chains
P2 Project Planning (Process Element 2)
Planning and managing product/process development projects — ensuring requirements are understood before execution.
| # | Audit Question | Objective Evidence | Status |
|---|---|---|---|
| 1 | Customer Requirements Analysis: Are all customer requirements (technical, commercial, delivery) collected, documented, and communicated to all relevant departments? | Customer requirement documents, APQP checklists, requirement traceability matrices | YESNO |
| 2 | Risk Assessment for Project: ⚠ Has a comprehensive risk assessment been conducted for the project — including technical, commercial, supply, and capacity risks? | Project risk registers, FMEA documents, risk mitigation plans | YESNO |
| 3 | Project Plan & Milestones: Is there a documented project plan with defined milestones, responsibilities, and deadlines? Are milestones met? | Project plans (Gantt), milestone review records, APQP timing plans | YESNO |
| 4 | Resource Planning: Are necessary resources (personnel, equipment, budget, tooling) planned and allocated for the project lifecycle? | Resource plans, budget approvals, equipment procurement records | YESNO |
| 5 | Change Management During Project: Are project changes documented, evaluated for impact, approved, and communicated to all stakeholders? | Engineering change requests, impact assessments, approval records | YESNO |
P3 Product & Process Design (Process Element 3)
Designing the product and manufacturing process to meet all requirements — before production begins.
| # | Audit Question | Objective Evidence | Status |
|---|---|---|---|
| 6 | Design FMEA (DFMEA): ⚠ Is a DFMEA conducted and maintained? Are severity, occurrence, and detection rated? Are action priorities defined? | DFMEA documents, review/update records, action item tracking | YESNO |
| 7 | Process FMEA (PFMEA): ⚠ Is a PFMEA conducted for the manufacturing process? Are all failure modes identified with severity/occurrence/detection ratings? | PFMEA documents, process flow linkage, action tracking | YESNO |
| 8 | Process Flow Chart: Is there a detailed process flow chart covering all operations from incoming material to shipping? | Process flow diagrams, alignment with PFMEA and control plan | YESNO |
| 9 | Control Plan: Is a control plan established covering setup, in-process, and final inspection — with methods, frequencies, and reaction plans? | Control plans for each product family, linkage to PFMEA and flow | YESNO |
| 10 | Work Instructions: Are visual, step-by-step work instructions available at each workstation — in the operator's language? | Work instructions at point of use, visual aids, operator comprehension | YESNO |
P4 Supplier Management (Process Element 4)
Ensuring the supply base is capable and controlled — from selection through ongoing monitoring.
| # | Audit Question | Objective Evidence | Status |
|---|---|---|---|
| 11 | Supplier Selection Process: Are suppliers selected based on defined criteria (quality, cost, delivery, technology)? Are selection decisions documented? | Supplier evaluation records, selection matrices, approval documents | YESNO |
| 12 | Supplier Quality Agreements: ⚠ Are quality assurance agreements (QAA) signed with all critical suppliers? Do they define escalation and recall procedures? | Signed quality agreements, escalation matrices, recall procedures | YESNO |
| 13 | Incoming Inspection: Is incoming material inspected per the inspection plan? Are results documented? Is nonconforming material quarantined? | Incoming inspection records, quarantine area procedures, NCRs | YESNO |
| 14 | Supplier Performance Monitoring: Are supplier scorecards maintained? Is performance reviewed with suppliers regularly? Are improvement plans in place for underperformers? | Supplier scorecards, review meeting minutes, improvement plans | YESNO |
| 15 | Supply Chain Risk: ⚠ Has a supply chain risk analysis been conducted? Are there contingency plans for critical single-source components? | Supply chain risk register, contingency plans, dual-source strategies | YESNO |
P5 Production Process (Process Element 5)
The heart of VDA 6.3 — auditing the actual production process on the shop floor.
| # | Audit Question | Objective Evidence | Status |
|---|---|---|---|
| 16 | Process Capability (Cpk): ⚠ Are Cpk studies conducted for all critical characteristics? Is Cpk ≥ 1.33 for stable and ≥ 1.67 for new/critical processes? | Cpk/Ppk reports, control charts, capability data by parameter | YESNO |
| 17 | Measurement System Analysis (MSA): ⚠ Is gage R&R ≤ 10% for critical measurements? Are MSA studies repeated after equipment changes? | MSA reports, gage R&R studies, recalibration after change records | YESNO |
| 18 | Equipment Maintenance: Is there a preventive maintenance system? Are maintenance intervals followed? Is equipment availability tracked? | PM schedules, maintenance logs, OEE data, downtime records | YESNO |
| 19 | Set-up & First Article Inspection: Are set-ups verified? Is first article inspection (FAI) conducted and documented before production runs? | FAI reports, set-up verification records, first-off/last-off procedures | YESNO |
| 20 | Personnel Qualification: Are operators trained, qualified, and certified for their tasks? Is a competency matrix maintained? | Competency matrices, training records, operator certifications | YESNO |
| 21 | Identification & Traceability: Are products identified and traceable throughout the entire process? Is nonconforming product clearly segregated? | Labeling systems, traceability records, red-tag quarantine areas | YESNO |
| 22 | Customer-Specific Requirements (CSR): ⚠ Are all customer-specific requirements identified, documented in the control plan, and verified in production? | CSR documents, control plan references, production verification records | YESNO |
P6 Process Results / Output (Process Element 6)
Evaluating the results and outputs of the production process — defects, efficiency, and delivery performance.
| # | Audit Question | Objective Evidence | Status |
|---|---|---|---|
| 23 | Defect Rate (PPM): ⚠ Is the PPM defect rate within target? Are defects categorized, trended, and acted upon? | PPM data, defect Pareto charts, improvement action records | YESNO |
| 24 | Process Efficiency (OEE): Is Overall Equipment Effectiveness measured and trended? Is OEE ≥ 85%? Are improvement actions triggered by low OEE? | OEE dashboards, availability/performance/quality data, improvement plans | YESNO |
| 25 | Delivery Performance: Is OTD (On-Time Delivery) ≥ 98%? Are root causes analyzed for late deliveries? | OTD data, delivery trend charts, corrective action records for misses | YESNO |
P7 Customer Satisfaction & Service (Process Element 7)
Post-delivery performance — how the customer experiences your output.
| # | Audit Question | Objective Evidence | Status |
|---|---|---|---|
| 26 | Customer Complaint Management: ⚠ Are customer complaints documented, root-caused (8D), and resolved within agreed timelines? Is 8D effectiveness verified? | 8D reports, complaint logs, response time data, effectiveness checks | YESNO |
| 27 | Customer Satisfaction Measurement: Is customer satisfaction systematically measured and reviewed? Are improvement actions derived from results? | Satisfaction surveys, customer scorecards, improvement plans from feedback | YESNO |
| 28 | Service & Field Performance: Is field performance (warranty, returns, field failures) tracked and fed back into the FMEA and CAPA processes? | Warranty data, field return analysis, feedback loop to PFMEA/design | YESNO |
Compliance Calculation
Total YES answers: ___ / 28
Compliance rate: (YES ÷ 28) × 100 = ___%
VDA 6.3 rating: ≥ 90% = conforming (FA) | 80-89% = conditional (FB) | < 80% = non-conforming (FC)
⚠ Critical questions (marked above): Any NO answer on a critical question (⚠) must be escalated immediately, regardless of overall score.
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