Vda6 5en

6
VDA
Quality Management
in the Automotive Industry
Product Audit Part 5
Table of contents
st
1 Edition 1998
Product Audit
st
1 Edition 1998
Verband der Automobilindustrie e.V. (VDA)

ISSN 0943-9412
Copyright 1998 by
Verband der Automobilindustrie e.V. (VDA)

(Association of the German Automotive Industry)
Quality Management Center (QMC)
D-60325 Frankfurt am Main, Lindenstrae 5
Online production:
VDA-QMC
D-60325 Frankfurt am Main, Lindenstrae 5
2
Liability exclusion
The VDA volumes are guidelines available for anyone to use. It is the res-
ponsibility of the person using the guidelines to ensure its correct use in
each specific case.
The VDA volumes take into account state of the art technology, current at
the time of issue. By using the VDA guideline, nobody is relieved of the
responsibility for their own actions. Each person acts, in this respect, at
their own risk. Liability by VDA, and those persons involved in issuing VDA
guidelines, is hereby excluded.
If during the use of VDA guidelines, errors or the possibility of misinterpre-

tation are found, it is requested that these be notified to the VDA imme-
diately, so that any possible faults can be corrected.
Referenced standards
The extracts from standards identified with their DIN number and issue
date are reproduced with the permission of the DIN Deutsches Institut fr
Normung e.V. (German Institute for Standardization). The version with the
latest issue date is definitive for the use of the standard, which can be
attained from the publishers Beuth Verlag GmbH, 10772 Berlin.
Copyright
The publication, including all its parts, is protected by copyright. Any use
outside of the narrow boundaries of copyright law, without the written
permission of the VDA, is unauthorized and illegal. This applies in
particular to copying, translation, microfilming and the saving and
processing in electronic systems.
3
Foreword
With respect to technical and economic progress, quality assurance deter-

mines the future of the automotive and supplier industry.
The production process consisting of many individual processes has to take

into account rational and economic aspects in order to achieve an optimum
in quality, time and costs. To ensure this, the VDA has issued the following
guidelines for the quality standard of the automotive industry:
QUALITY STANDARD
OF THE GERMAN AUTOMOTIVE INDUSTRY (VDA 6)
VDA 6 VDA 6 Quality System Audit

VDA 6 Part 1 Quality System Audit Part 2 Services
Quality VDA 6
Audits Part 3 Process Audit
VDA 6 VDA 6 Product Audit

Basics Part 5 Product Audit Part 6 Services
The product audit shall demonstrate the quality niveau of internally/exter-

nally manufactured products in a process chain.
With knowledge of the quality niveau, short and long term conclusions
regarding the production process and if necessary, the quality system are
possible.
The information gained from product audits promote the continuos process
of quality improvement, to the benefit of customers and suppliers.
A practical representation of the product audit was chosen, to make the

content of the publication easily understandable.
Guidelines are provided for the planner of product audits and product
auditors.
The subject Product Audit is then rounded off with actual examples from
practice.
4
We thank the following involved companies and their employees for their
input in the preparation of this publication:
Aktiengesellschaft Khnle, Kopp & Kausch, Kirchheimbolanden

Continental AG, Hannover
Fichtel & Sachs AG, Schweinfurt
Ford-Werke AG, Cologne
GLYCO-METALL-WERKE Glyco B.V & Co. KG, Wiesbaden
Daimler-Benz AG, Hamburg Works
TRW Deutschland GmbH, Motor Components, Barsinghausen
THYSSEN KRUPP STAHL AG, Duisburg
Volkswagen AG, Wolfsburg
ZDH-ZERT e.V., Bonn.
and hope, that this publication finds successful application.
Frankfurt/Main, April 1998
VERBAND DER AUTOMOBILINDUSTRIE E. V. (VDA)
5
Table of contents Page
Foreword 4
1 Introduction 9
2 Definitions and Purpose of a Product Audit 11

2.1 Definitions 11
2.1.1 Quality Audit (according. to ISO 8402 : 1994) 11
2.1.2 Product (according to ISO 8402 : 1994) 11
2.1.3 Product Audit 12
2.2 Purpose 13
3 Product Audit at Car Manufacturers and Suppliers 14

3.1 Distinguishing a Product Audit from other Audit Types 14
3.2 Process of a Product Audit 16
4 Preparation and Planning of Product Audits 17

4.1 Preconditions and Responsibilities 17
4.3 Reference Documentation 18
4.4 Inspection, Measuring and Test Methods and Equipment 19
4.5 Auditor Qualification 19
5 Product Audit Questionnaire 20

5.1 General 20
5.2 Questions to the Physical Examination of a Product 20
5.2.1 Review of all Documents 20
5.2.2 Random Sampling 20
6 Performing a Product Audit 21

6.1 Responsibility 21
6.2 Process 21
6.3 Reporting (Documenting) 22
7 Analysis of the Data and Investigation of Causes of

Nonconformities 23
8 Evaluation of the Product Audit Results 24
9 Product Audit Report 25
6
10 Corrective Actions Resulting from the Production Audit 26
10.1 General 26
10.1.1 Corrective Actions for Major Nonconformities 26
10.1.2 Corrective Actions for Minor Nonconformities 26
10.2 Monitoring of Corrective Actions 26
11 Case Examples 27
11.1 Case Example Selector Shaft - Mller + Co. 27
11.2 Case Example Input Material (Sheet metal)
- Thyssen Stahl AG 33
11.3 Case Example Laser and Mash Seam Welded Tailored Blanks
- Thyssen Stahl AG
11.3.1 Selecting Samples for Inspection 38
11.3.2 Scope of Inspection 38
11.3.3 Process and Sequence of Operations 38
11.3.4 Product Audit Report 39
11.3.5 Procedure for Handling Nonconformities 39
11.3.6 Dispatch Audit 40
11.3.7 Responsibility 40
11.4 Case Example Bearing Bush - AG Khnle, Kopp & Kausch 43
11.4.1 Explanation Systematic Quality Evaluation Production
and Purchasing (SQPP) 43
11.4.2 Code Number System for SQPP 45
11.4.3 Procedure using Bearing Bush as an Example 47
11.5 Case Example Valves - TRW Deutschland GmbH,
Motor Components 54
11.6 Case Example Tires - Continental AG 59
11.6.1 Scope and Frequency of Inspection 59
11.6.2 Specifications, Inspection, Measuring and Test Methods 59
11.6.3 Process 60
11.6.3.1 Auditor 60
11.6.3.2 Visual Inspection 60
11.6.3.3 Machine Tests 60
11.6.4 Documentation 60
11.6.5 Evaluation 60
11.6.6 Forms 60
11.6.6.1 Visual Inspection 60
11.6.6.2 Concentricity 60
7
11.7 Case Example Complete Vehicle - FORD AG 63
11.7.1 Check of Conformity 63
11.7.2 Complete Vehicle 63
11.8 Case Example Complete Vehicle - Volkswagen AG 72
11.9 Example of a Product Audit Procedure - Mercedes Benz AG,
Hamburg Works 79
11.9.1 Purpose 79
11.9.2 Scope 79
11.9.3 Terms and Definitions 79
11.9.3.1 Product Audit 79
11.9.4 Responsibilities 80
11.9.4.1 Product Audit 80
11.9.5 Description 81
11.9.5.1 Performing the Product Audit 81
11.9.5.2 Product Audit Plan 82
11.9.6 Additional Notes 82
11.9.7 Applicable Documents 82
11.9.8 Flow Chart of the Product Audit Process 83
12 Appendix: Reference to VDA 6.1 86
13 Bibliography 89
13.1 Standards 89
13.1.1 DIN EN ISO 8402 (1995) 89
13.1.2 DIN EN ISO 9000, Part 1 (08/94) 89
13.1.3 DIN EN ISO 9000, Part 2 (03/92) 89
13.1.4 DIN EN ISO 9001 (08/94) 89
13.1.5 DIN EN ISO 9002 (08/94) 89
13.1.6 DIN EN ISO 9004, Part 1 (08/94) 89
13.1.7 DIN ISO 10011 Part 1 (06/92) 90
13.1.8 DIN ISO 10011 Part 2 (06/92) 90
13.1.9 DIN ISO 10011 Part 3 (06/92) 90
13.2 Literature 90
13.2.1 VDA Publications for the Automotive Industry 90
13.2.2 Masing, Walter (Publ.) 91
13.2.3 DGQ-Publication 11 - 04 (Status 1995) 91
13.2.7 DGQ-Publication 14-18 91
13.3 References 92
8
1 Introduction
A product audit assesses the effectiveness of quality assurance through the

examination of a small number of products and/or parts and confirms their
quality capability based on the quality of the product. Thereby, it is
checked, if the product complies with the given specifications, or
respectively, with special customer/supplier agreements.
The focus of the evaluation of deviations from the specification lies,

depending on the given objective, on its technical significance, its signifi-
cance for the subsequent process or customer reaction.
During a product audit, the product properties in new condition, and not
after long term use, are determined. It does not serve as a substitute for
inspections during the production process.
Product audits are carried out regularly. Irrespective of this, they can also
be additionally carried out for a specific reason. They must be planned and
prepared by qualified personnel, before they are carried out. Every audit,
its results, improvement measures, as well as responsibilities are to be
documented.
Product audits can be carried out in all business processes like,
product development product manufacturing - product marketing.
This publication primarily deals with product audits in product manufac-

turing.
The product audit identifies quality trends and nonconformity focal points.
In certain cases, it can lead to the conclusion that system failures exist,
which then initiates further audits such as process or system audits being
carried out.
Product audits are an integral part of a quality system according to

VDA 6.1. The company management must identify with the duties and ob-
jectives of the product audit.
9
The following decision criteria can be useful for the application of product
audits in a company:
- checking the compliance of development results with the in-

puts (e.g. prototypes, pilot production runs)
- verifying the uniformity of production
- recognizing deviations, changes and trends
- discovering risk potential
- illustrating customer reaction
- decision aid to customer expectations and requirements
- earliest reaction to field problems
- checking the effectiveness of measures taken
- legal requirements.
An important precondition for the performance of product audits is the

availability of an appropriately organized structure, that allows audits to be
systematically and independently carried out.
The audit plan defines at which stage in the production process, product
audits are carried out. In the audit plan, questions about the efficiency,
complexity of the products and the number of production pieces are
included.
10
2 Definitions and Purpose of a Product Audit
2.1 Definitions
2.1.1 Quality Audit (according. to ISO 8402 : 1994)
Systematic and independent examination, in order to ascertain, if the

quality activities and related results, comply with given instructions, and if
these instructions are efficiently put into action and are suitable to achieve
their objectives.
Note: A quality audit is typically carried out on a quality system or an element

thereof, on processes or products (including services), but is not restricted to
these. Such quality audits are often called system audits, process audits,
product audits, or service audits.
One purpose of a quality audit is to assess the need for an improvement or
corrective action. A quality audit should not be mistaken with quality
monitoring activities or reviews, which are carried out for process control or
product receiving purposes.
Quality audits can be carried out for internal or external purposes.
2.1.2 Product (according to ISO 8402 : 1994)
Result of activities and processes.
Note: The term product can include a service, hardware, processed materials,
software or a combination thereof.
A product can be tangible (e.g. assemblies, processed materials) or
intangible (e.g. knowledge or concepts) or a combination thereof.
A product can be intended (e.g. product offered to customers) or unintended
(e.g. pollutants or undesirable effects).
11
2.1.3 Product Audit
A p r o d u c t a u d i t is the planning, performance, evaluation

and documentation of e x a m i n a t i o n s
of - quantitative and qualitative characteristics

on - material products
after - completion of a production stage
and before - its forwarding to the next customer
(internal/external)
on the basis - of reference values
through - an independent auditor.
Note 1: Material p r o d u c t s are the result of activities and processes and are, for
example, raw materials, intermediate products of all types including com-
ponents, assemblies, and subassemblies, as well as end products, which are
to be delivered to the customer. During a product audit, the properties in new
condition and not after long term use, are determined.
Note 2: Both internal or external c u s t o m e r s can be meant. One can also under-
stand customer to mean a further process or a subsequent production
machine.
Note 3: The product audit is generally carried out by the product manufacturer
(supplier). It is useful for the p e r f o r m a n c e o f a p r o d u c t a u d i t t o u s e
DIN ISO 10011 Part 1. The auditor must know the product and its production
process, or have access to information carriers. Furthermore, depending on
the objectives, he has information that describe customer reactions to
nonconformities.
The performance of the examinations follows a defined audit plan.
Note 4: According to the VDA publication Volume 6, Part 1, Question 15.1 the
following points are to be established in the product audit plan: type and
extent of samples or parts, type and number of the characteristics to be
checked, inspection, measuring and test method and equipment, and eva-
luation of the examination results in comparison to the internal and/or external
standards or specifications and drawings.
Note 5: The r e s u l t of the evaluation of a product audit is to be regarded as a rev i e w
of all quality control measures.
When deviations from the specifications are found, corrective actions are to
be taken. Immediate actions like e.g. stopping or re-sorting the entire
production and, if necessary, in development, are required, when deviations
from specified values and/or limit patterns of important characteristics
especially safety characteristics, are found.
12
Note 6: Product audits can be carried out on prototypes and after all production
phases until delivery. Audits at different production phases and, if applicable,
the delivery product audit performed from a customers point of view, are
methodically attuned to one another.
2.2 Purpose
It is the task of a product audit, to check normally delivery-ready products

according to the audit plan for conformance with the technical documents,
drawings, specification, standards, legal requirements and further set
quality characteristics. This check is carried out on few products, but very
comprehensively and from the customers point of view.
As a priority, system faults, nonconformity focal points and long term

quality trends are to be ascertained. For the elimination measures to be
implemented, recognized nonconformities are to be separated into syste-
matic and coincidental nonconformities. In serious cases, immediate
actions in the production process are implemented. The respective check
represents the momentary situation. The audit in its entirety over a time
period, shall illustrate the quality potential of the production. The scope of
inspection is determined by the complexity of the product and the number
of production pieces.
The purpose of a product audit, for a company, is to recognize deviations

and to confirm compliance with drawing requirements and customer speci-
fications. The results of reliability checks can also be included.
Knowledge of all customer expectations of a product is necessary during a

product audit. These should be externally evaluated and methodically
integrated into the product audit. In this way, for example, noises could be
evaluated to see if, and to what extent, they are regarded as disturbing by
the customer.
The supplier or manufacturer gains a comprehensive picture of the quality

of his products and the acceptance of these products by the customer.
13
3 Product Audit at Car Manufacturers and Suppliers
3.1 Distinguishing a Product Audit from other Audit Types
The product audit shows only partial similarities to other audit types or with
other product assessments. An exemplary distinction, which does not claim
to be exhaustive, is shown in Table 1.
14
Inspection verification
Product Audit System Audit Process Audit 100%inspection, Final inspection, SPC
measuring and testing measurement and First sample Works
testing in serial inspection
production certificate
Performance acc. to plan, generally acc. to plan, generally acc. to plan and as continuously continuously acc. to cust. acc. to cust. continuously
frequency several times a year once a year necessary requirements requirements
Checked selected acc. to elements of the quality selected, as necessary qualitative selected, product acc. to cust. selected, and selected, as required
characteristics customer requirements system for process evaluation characteristics, related, acc. to requirements acc. to cust. for process control
/expectations and incompetent customer expectations requirements
important process and characteristics
product characteristics
Capability short term capability of (degree of compliance short term capabilities of (qualitative short and long term acc. to customer requirements automatic
parameters the product with the system the process parameters characteristics e.g. cpk < capabilities of the identification of the
characteristics on the objectives) 1,33) product characteristics short and long term
basis of the selected capabilities
sample. Feedback to
production
Applied selected, specific for the document review selected, specific for the selected, specific for the selected standard selected with the agreement of the selected, specific for
verification product compared to the process product method, specific for the customer the process or product
methods objective, the application product
in practice
Qualification of knowledge of the DIN ISO 10011, Part 2 + knowledge of the knowledge of the knowledge of the knowledge of the characteristics, knowledge and
the auditors / product and production EOQ Certificate + process characteristics characteristics and customer requirements and experience of control
inspectors process, also from the VDA 6.1 Certificate customer expectations relevant standards card technology
customers point of view
Necessary drawings, specifications, quality manual, process plan, process catalog of deviations for catalog of deviations for specifications, drawings, quality control cards,
documents work and inspection procedures and work parameters, inspection qualitative qualitative inspection instructions, standards inspection instructions
instructions, coding instructions instructions characteristics, characteristics,
systems inspection instructions specifications, drawings,
inspection instructions
Documen- inspection results, audit results according to inspection record, audit statistics to inspection inspection record and first sample works control cards with
tation / records report questionnaire, audit report, nonconformity results, nonconformity statistics to inspection inspection inspection evaluation
report, nonconformity analysis with corrective analysis with corrective results, nonconformity report certificate
analysis with corrective actions actions analysis with corrective
actions actions
Table 1: Distinction between a product audit and other types of audits and inspections
15
3.2 Process of a Product Audit
The process of a product audit is schematically shown in the following.
Product Audit Process
Company Audit
specific Planning and preparation - date
requirements of schedule audits - responsible area
Kcustomer
specifications Inspection instructions
- characteristics
Drawings - inspection, measuring
and test equipment
- frequency
FMEA
Internal
nonconformity
Planning and
Customer preparation of
Market and complaints unscheduled audits *)
customer
information
Drawings Process
Record with
Inform responsible department
audit results
Inspection Product sampling
instruction Product inspection
Audit plan
Audit report
Protocol Evaluation
Long term
evaluation
No Corrective actions
Product Audit according to
satisfactory element18, VDA 6.1
Nonconformities
according to
audit report
Yes
Action plan
Yes No
Audit report Inform responsible departents
Long term Inclusion of results in

evaluation next audit planning
*) Unscheduled audits are specifically initiated.

They must therefore not be included in the long term evaluation.
If specific assesments are included in the long term evaluation,

it is distorted, as a specific assesment does not represent a random sample.
16
4 Preparation and Planning of Product Audits
4.1 Preconditions and Responsibilities

A product audit must be carefully planned. Therefore, certain preconditions
must be met:
a) Inclusion of a statement regarding the carrying out of product

audits in the quality manual
b) raising of an audit program
c) the translation of this into a binding work instruction for the audi-
tors.
Persons responsible for the planning of product audits, are those func-
tioning units in a company assigned accordingly in the quality manual. It
must be ensured that this area is independent of the producer.
4.2 Audit Program
Audit programs must be established for the products and must contain
following information:
- Purpose of the audit
- Reference documents
- Products to be audited
- Coding systems/Check lists
- Date / Frequency of the audit
- Auditors
- Report issuer with distribution list
- Responsibilities for following up of corrective actions.
During the raising of the audit plan details, amongst others, must be
given about:
- the characteristics to be checked
- quantitative characteristics
- functional characteristics
- material characteristics
- life time characteristics
- qualitative characteristics
and the inspection and testing methods and equipment to be applied.
17
The selection of the products and characteristics to be assessed is
made to, for example, the following criteria:
- lot size
- customer requirements
- product composition
- production line.
4.3 Reference Documentation
For a product audit, all technical documents containing integral parts of the
quality requirements are consulted. With the help of these documents, it
can be assessed if the quality requirements on the product are being
complied with. In particular, it involves e.g. following documents:
- Drawings with amendment status

- Specifications
- FMEA
- Production process plans and process descriptions,
- Inspection and testing specifications
- Nonconformity catalogs
- Limit patterns
- Instructions to the analysis methods
- Evaluation / quality standard or references
- Material sheets
- Approved production deviations (concessions)
- Standards
- Legal requirements (e.g. federal laws)
- If applicable, nonconformity classification (in e.g. major and
minor nonconformities) with evaluation
- Delivery agreements.
18
4.4 Inspection, Measuring and Test Methods and Equip-
ment
When selecting inspection, measuring and test methods and equipment,

the following basics and comments have to be considered:
- measuring uncertainty of the inspection, measuring and test

equipment
- with alternative inspection, measuring and test methods, the
one to be selected should be one not used in the serial inspec-
tion, in this way, weaknesses due to incorrect or uncertain
inspection, measuring and test equipment can be recognized.
- with qualitative inspections, measuring and tests, limit patterns
and constant training of the auditors is necessary
- in order to keep the basis of the evaluation universal and con-
stant, it should be frequently compared to the requirements
and/or the auditors changed and the above documented.
4.5 Auditor Qualification
The success of a product audit depends to a large extent, on the technical

and human qualifications of the auditor. Hereto belong, amongst others:
- knowledge of the purpose of the product audit

- product and quality specific knowledge
- use of inspection, measuring and test specifications
- mastery of inspection, measuring and test techniques
- handling of nonconformity catalogs
- evaluating of products
- reporting
- physical suitability (eye sight test etc.)
- good intelligence
- good intuition
- personal reliability
- practical experience in manufacturing
- knowledge of production processes, and or their application
- knowledge of, and access to, information about customer
expectations
19
5 Product Audit Questionnaire
5.1 General
In order to ensure the successful performance of a product audit, thorough

planning must first be carried out. Therefore, it is necessary for the audit,
irrespective of whether product audits are carried out regularly or for a
specific reason, to establish a questionnaire related to the area of appli-
cation in the form of a specified/actual value comparison.
The majority of questions are to be worded in such a way, that the answer
may not only be Yes or No, but that detailed information must be pro-
vided.
5.2 Questions to the Physical Examination of a Product
This procedure is based mainly on the examination of geometrical and

functional quality characteristics of products or individual parts (and to a
limited extent, also material characteristics).
5.2.1 Review of all Documents
With the help of questions, the following, e.g. is to be clarified:

- Has the accuracy of the drawing been checked?
- Are any more specifications and standards applicable?
- Which part is examined with which revision index?
- Does the part have a serial number?
- Where was the part taken from?
- Which production area does it originate from?
- When was it produced?
5.2.2 Random Sampling
Following a fixed sampling instruction and after determining if the test

subject complies with the quality requirements, the following, for example,
should be clarified
- Which nonconformities have been established?
- What is their significance?
- How is each nonconformity to be evaluated?
20
6 Performing a Product Audit
6.1 Responsibility
It has to be ensured, that the product audits are performed by an indepen-

dent body.
Product audits can be carried out in the following areas:
- at the manufacturer
- at the customer.
The responsibilities for the performance of the product audit lies, primarily,
with the product manufacturer. In exceptional cases, product audits may
also be performed by the recipient (customer) or in special cases by neutral
bodies (external testing laboratories).
As and when necessary, the supplier and customer (internal, external)

should coordinate, in order to make use of the findings to promote product
quality.
6.2 Process
For the audit process, the following regulations have proven successful:
- During an audit, the relevant departments are informed only at

short notice about the sampling of the products.
- When an audit is carried out for a specific reason, an

additional measure may be that the lot, from which the
samples were taken, is placed on hold until completion of the
audit.
- Products which have been taken as samples during an audit,

must be reallocated carefully, if reused, in order to prevent
mix ups with similar products. Thereby, the products have to
be brought back to their original status, i.e. corrosion risks,
specified packaging and so on, have to be taken into account.
21
- If nonconformities are found on safety features, immediate
corrective action is to be taken. Thereby it has to be ensured,
that no nonconforming products are returned to the system.
6.3 Reporting (Documenting)
The results of the product audit are documented by the auditor in an audit
report: See also page 29 and subsequent pages Case studies of various
companies.
22
7 Analysis of the Data and Investigation of Causes of
Nonconformities
The main aim of a product audit is to gain information about the quality
niveau of a product or individual parts, to monitor it over an extended
period of time and to draw conclusions from the results for the future.
This can be done with quality value numbers. The course of the quality
value numbers (QVN QWZ in German) is, in practice, often split into and
evaluated in three categories. These categories are:
- regular Course of the QVN within two

limits (controlled processes)
- irregular Course of the QVN slightly

exceeds the upper and/or
lower limit
- strongly fluctuating Course of the QVN indicates an

uncontrolled production process
A nonconformity analysis allows conclusions to be drawn about the causes

of the nonconformity according to the five Ms (Man, Machine, Material,
Method, Means/Environment).
In addition to the actual product audit report, evaluations of nonconformity

focal point are gaining more importance. The product quality can be
demonstrated by these, as well as by using the attached diagrams.
23
8 Evaluation of the Product Audit Results
The evaluation of the product audit results is individual, differs from one
product to the next and depends on the use of the product. It is important,
however, that the evaluation method is kept constant for an extended
period of time to allow comparison.
It is important for the systematics of the evaluation, that one differentiates

according to the following characteristics:
- quantitative (measurable) characteristics

- functional characteristics
- material characteristics
- life time characteristics
- qualitative characteristics.
The evaluation of the results should be made from a statistical point of

view. When evaluating quantitative characteristics, the presentation of the
mean value in connection with the spread is a suitable method. Additional
diagrams show the correlation even more clearly.
Where possible, for example, Pareto-Analysis can be used to establish

nonconformity focal points.
The evaluation of the questionnaire provides an indication of the quality

niveau of a product through
- compliance or noncompliance with the product characteristics

- type and location of the nonconformity
- extent of the nonconformity (e.g. critical, major, minor)
- detectability (e.g. probability of discovery high/low).
For evaluations summarizing quantitative and qualitative characteristics,

weighting factors can be established and applied. Often, they are used to
establish quality value numbers, which are listed for comparison and are
drawn upon for product evaluations.
24
9 Product Audit Report
The product audit report encompasses:
- statements on the number of parts or end products examined

and those found to be nonconforming.
- All nonconformities found are to be classified, if stated.
- The classified and weighted results of the product audit should

be condensed to one or several Quality Value Number (QVN),
depending on their objective, to allow comparative assess-
ments and to continually record trend.
- the reasons that led to production stop, including the

comments to the noncompliance of the quality requirements.
The characteristics, that make corrective actions necessary, are to be

pointed out in the audit report. In any case, the results are to be included in
the long term assessment of the product quality.
The auditor writes the audit report and co-ordinates the corrective actions
with the person responsible for production.
The audit report is to be distributed to the responsible departments as well

as to the responsible product management.
The audit reports are to be archived following given regulations (see also
VDA Volume 1 and Volume 6, part 1).
25
10 Corrective Actions Resulting from the Production
Audit
10.1 General
Corrective actions are to be introduced, based on the audit report. Thereby,

the procedure described in the VDA Volume Part 1, Element 18 (Questions
18.01 to 18.04) is to be followed.
The corrective actions to be taken have differing significance; they depend
on the severity, frequency and type of nonconformity.
Only by knowing the causes of the nonconformities, can efficient corrective
actions be introduced. The following corrective actions, if given, can be
distinguished at a product audit:
10.1.1 Corrective Actions for Major Nonconformities
Major nonconformities cause immediate action to be initiated to determine

the cause of the nonconformity and to eliminate it. All affected compo-
nents, semi-finished products or products must be put on hold immediately.
If nonconforming parts are reworked, they must undergo reinspection.
10.1.2 Corrective Actions for Minor Nonconformities
Dependant on the impact of the nonconformity, a concession (internal/ex-

ternal) has to be obtained for the stock in circulation and dispatch.
10.2 Monitoring of Corrective Actions
Corrective actions to be implemented, are to be laid down in writing inclu-

ding a set date, e.g. when the actions have to have been taken.
The auditor is not responsible for the implementation of the corrective
actions.
The monitoring of the implemented corrective actions may require an
unscheduled product audit. In addition, unscheduled process and/or system
audits may be required, if the causes of nonconformity cannot be clearly
determined.
26
11 Case Examples
In the following, some case examples for product audits from practice are
shown, which are meant as supplements to the theoretical explanations.
The chosen products extend from single parts, complete assemblies
through to finished vehicles. The differing procedures and evaluation
methods illustrate the scope for the user. The varying products in the
automotive industry and the partially differing objectives for the product
audit, do not allow the use of a uniform system. However, from the multi-
tude of given possibilities, a concept can be put together appropriate to
ones own requirements and objectives.
Example No. Company Product

11.1 Mller + Co. Selector shaft
11.2 Thyssen Krupp Input material (Thin sheet metal)
11.3 Thyssen Krupp Laser and mash seam welded tailored blanks
11.4 KKK Bearing bush
11.5 TRW Valves
11.6 Continental Tires
11.7 Ford Complete Vehicle
11.8 VW Complete Vehicle
11.9 Daimler-Benz Procedure
Table 2: Summary of the Case Examples for Product Audits
11.1 Case Example Selector Shaft - Mller + Co.
Explanations
The inspection guideline 013-1 (Fig. 11-1-1) is generally valid for selector
shafts of the same design and contains the description of inspection,
measuring and test activities to be carried out, as well as the assigned
inspection sequence number.
The test pieces are selected from the dispatch department in accordance
with the sampling plan.
Inspection plan/Log sheets 27/1095 (Fig. 11-1-2):
27
The inspection plan is raised specific to the part by the quality department,
it serves additionally for the recording of the inspection results. Noncon-
formities found are classified according to their significance and registered
with a corresponding code letter - A-, B- or C-Nonconformity. For the eva-
luation of the nonconformity points (NP), the three nonconformity catego-
ries are assigned with different nonconformity weighting factors:
A - Nonconformity = 10 Critical nonconformity
B - Nonconformity = 5 Major nonconformity
C - Nonconformity = 1 Minor nonconformity
The sum of nonconformity points (NP) =
(no. of nonconformities x nonconformity weighting factor).
The inspection report contains in essence:

- sampling date
- sampling location
- completion date of the test pieces.
Identifying the completion date of the test pieces is, above all, important
for narrowing down the nonconformity and establishing the corrective
actions. The identifying of the number of nonconformities and the noncon-
formity points (NP) is necessary for the overall evaluation.
In the given field, the number of A-, B- and C-Nonconformities are noted
against the inspection sequences, the number of nonconformities and non-
conformity focal points are calculated.
Identifying the Quality Code Number : (QCN)
QCN = 100 Nonconformity points/Test pieces
In the example, 4 test pieces showed 7 nonconformities with 51 nonconfor-
mity points.
QCN = 100 - (51/4) =100 - 12,75
QCN = 87,25
Note: As the views about the value of a quality code number for comparisons differ, the user
must decide if he should state a QCN in a report. The QCN can also be calculated to
a different formula to the one given in the example.
The following are represented:

Fig. 11-1-1: Inspection Guideline
11-1-2: Inspection Plan
11-1-3 + 4: Inspection Report (Front page/Back page)
28
Mller + Co. Product Audit
Quality Assurance Inspection Guideline 013-1
Inspection Description of the activity or inspection
Sequence
100 Sampling of the test pieces
Sampling is to be carried out at random, test pieces are to be taken from a
delivery-ready lot of the latest production date.
200 Check of the packaging
- Appropriate for the purpose in accordance with specification
- Marking in accordance with specification
- Safety against damage to the product
- Inspection certificate available for the customer
300 Visual inspection
-Preparation : Number the taken test pieces
-Inspection : Appearance, surface, marking according to drawing requirements
400 Dimensional inspection
Selected dimensions according to customer and manufacturer drawing
500 Production , gauging , fitting checks
600 Check of physical properties

- Strength, hardness etc.
- Heat -, cold resistance.
- Torque and other moments of force according to requirement
- Inspection certificate of the supplier available and satisfactory
700 Check of chemical properties
So far as required and so far as the usability of the product is influenced.
- Material inspection
- Inspection certificate of the supplier available and satisfactory.
800 Reliability checks
Long term tests according to specification
Abrasion test
If applicable, availability of the inspection certificate
900 Establishing the results after entry in the audit report
- Discussion of the nonconformity points (NP), no. of nonconformities x weight
- Discussion of the quality characteristic number (QCN)
Department Name Date Revised on by
WQ4 Meier 19.10.94 21.11.1994 Schulze
Fig. 11-1-1: Inspection Guideline
29
Quality Assurance Inspection Log sheet 27/1095
Plan
Description of part: Selector shaft Manufacturer part no. 123.156 Ind. 2 v. 01.10.1995
Customer: Schulze GmbH Customer part no. 189.101 Ind. 11 v. 27.09.1995
Operation: Complete assembly sketch
Insp. Inspection Insp. meas.

seq. characteristics & test equip n 1 2 3 4 5 6 7 8 9 10 NP QCN
Specified values =
205 Marking/Identification Visual 4
210 Packaging according Visual 4

to specification
305 Selector shaft Visual 4 10
perfectly riveted to the
lever
310 Pin perfectly pushed Visual 4 5
in, free of burrs
405 2 x Angle 90 30 Goniometer 4
410 Angle 15 30 Goniometer 4
415 Shaft 12.894..12 Dial gauge 4 6
420 Dimension 264 0,25 Caliper gauge 4
425 Dimension 61 - 0,25 Caliper gauge 4
505 Lever position, Setting 4 30
location, gauge
countersinking
510 Parallelism Gauge 4
Hole spacing
605 Torque Torsional 4
00 NM min. spanner
610 Case hardness Hardness test 4
705 Inspection certificate Visual 4
for chemical analysis
805 Abrasion resistance Facility 4
acc. specification
A40563
Auditor Date Nonconf cat. Nonconf. weight NP QCN
Ott 13.10.1995 51 87,3
Fig. 11-1-2: Inspection plan
30
Quality Assurance Inspection Report No.: 27 / 1095
Description of part: Selector shaft Manufacturer part no. 123.156 Ind. 2 v. 01.10.1995
Customer: Schulze GmbH Customer part no. 189.101 Ind. 11 v. 27.09.1995
Goods extracted on: 12.10.1995
Goods extracted from: Dispatch dept.
Completion date: 03.05.1995
Insp. Inspection No. of Nonconf. No. of Noncon
seq. performed n Cat A Cat B Cat C Nonconf. f. points
200 Packaging 4 - - - -
300 Visual inspection 4 1 (x 10) 1 (x 5) - 2 15
400 Dimensional insp. 4 - 1 (x 5) 1x1 2 6
500 Gauging 4 3 (x 10) - - 3 30
600 Physical 4 - - - -
properties
700 Chemical 4 - - - -
properties
800 Reliability checks - - - -
900 Result 7 51= NP 87,3 = QCN
Decision: Release p Placed on hold x
Summary:
Placed on hold due to nonconformities in the inspection sequence:
209: Riveting not satisfactory. The lever does not sit securely on the shaft.
419: The hole spacing is exceeded according to the gauge.
Further action required: Yes x Nop
Yes No
Stock placed on hold X through Q 12 by immediately
Corrective actions to be initiated X through P 11 by immediately
Drawing/Work plan amendment
to be ordered X through by
Comments
see overleaf from on
Auditor : Ott Date: 13.10.95
Distribution: a 12, P 1, P 11, P 124
Fig. 11-1-3: Inspection Report / Front Page
31
Back page Inspection Report No. 27/1095
Acknowledgement from: P 11 to: P 1 and Q 12
Agreement with the assessment
Yes No
Corrective Nonconformity eliminated since production date 14.10.95

action Amendment record no. 511 X from P 124
Notice no. 012/1095 from P 11
Concession no. 2/2/Q1 from a 1 reg. Insp. sequence 315
(C-Nonconformity)
Stock check Stock in store X Nonconformity share : 0,5% of 200

inspected pieces
Stock in circulation X Nonconformity share 2% of 50
Goods exit X inspected pieces
Nonconformity share 0 of 75
inspected pieces
Amendment s Drawing will be changed X by ...
Production plan will be X by ...

changed
Customer Warranty complaints notified X from...

complaints
Actions at the customer
premises on ...
X
Cause of nonconformity, corrective action or reason for rejection:
CF 1: Pressure plate and riveting device corrected

Drilling device newly adjusted and new bushes fitted
Personnel instructed
Stock in store and circulation sorted and reworked
Date: 19.10.95 Name: Thiebel Identification Symbol: P 11
Fig. 11-1-4: Inspection Report Bac

/ k Page
32
11.2 Case Example Input Material (Sheet metal)
- Thyssen Stahl AG
Explanation
Product audits are carried out in the form of an internal company re-inspec-
tion (Fig. 11-2-1). The scope of inspection amounts to 20 coils (rolls)
monthly per working area. The product range consists of the following:
- cold rolled sheet metal (KB)

- hot galvanized sheet metal (Z)
- galvannealed (ZF)
- electrolytic galvanized sheet metal (ZE)
- hot aluminized sheet metal (AS)
- coil coated sheet metal (OC)
- other (SO).
The selection of the test pieces is carried out in accordance with the in-
structions of the responsible quality department.
Generally, coils packed and ready for dispatch are examined.
The characteristics to be inspected are laid down in a questionnaire. The

inspection is carried out on the basis of the given characteristic specifica-
tions. The characteristics are assigned with position numbers (Pos.-No.)
e.g. 011-Labelling, 301 not sufficiently oiled (Fig. 11-2-1).
The evaluation scheme is made up of a 5-stage grid, against which each

nonconformity is evaluated. For each nonconformity given 5 or more non-
conformity points, the cause and corresponding corrective action are to be
named. (Fig.11-2-2)
Reporting takes place monthly by the auditor. The monthly results are pre-
sented for each working area and supplemented with action plans.
The audit result is represented in Fig.11-2-3 and 11-2-4.
33
Product Audit Process
Input Material (Thin Sheet Metal)
Spezification
Planning
international company
re-inspection Checklist
(Inspection characteristics
Work instructions
- characteristics
- inspection, measuring and
test equipment
- frequency
Requirement
Selection of test pieces Quality department
Process Work instructions
Evaluation
>5 Nonconformity points? No Reporting
Yes
Immediate actions
Corrective actions
Bild 11-2-1: Product Audit Reinsepection Work Process
34
PRODUCT AUDIT REINSPECTION Page No.: ___ of _
Individual evaluation Insp. Date _______
KW I / KW II
Product: Order / Pos.: Customer: Ident. No.:
DIN-Quality: Order Width: Order Thickness: Packet No.:
SPECIFICED VALUES
Tol. Width +/- Surface type Pack. weight min Edge trim
Tol. Thickness +/- Evenness Pack. weight max Welding
SG Protection Type of packaging
Cust. Standard Stamping Inner- No. of labels i: o:
Surface finish Stable side Outer- min. Type
of labels
Application Outer- max.
Other + Source details
Evaluation
Explanation Assessment
step
n 55 min. 1 nonconf. with 55 points Rejection of the insp.unit, further processing at cust. premises not
n 15 min. 1 nonconf. with 15 points poss.
n 5 min. 1 nonconf. with 5 points Partial rejection, Repair/rework prior to delivery necessary
n 3 min. 1 nonconf. with 3 points Throughput at cust. premises only poss. with add.costs (e.g extra
n 0 no nonconfs. equals 0 points oiling)
Throughput at cust. premises without difficulty, cosmetic faults
Reinspection complies with the release results/ cust. requirements.
Pos Inspected Method Nonconf. points n Comments
characteristic 55 15 5 3 0
011 Labeling visual
051 Packaging visual
101 Coil status visual
102 Coil edges visual
103 Outer winding visual
104 Inner winding visual
152 Coil Inner tape
measure
153 Coil Weight scales
201 Edge trimming visual
251 Ident. / stamping visual
301 Surface protection visual
351 Coil width automatic
352 Coil thickness automatic
401 Surface finish/coat. visual
402 Surface type/class visual
404 Evenness visual
451 Weld seam visual
501 Stable side visual
Corrective actions for nonconformity points n 5:
Reinspection carried out

Name/Signature Datum
Repair carried out

Name/Signature Date
Fig. 11-2-2: Product Audit Reinspection: Individual Evaluation(Form)
35
Product audit - Reinspection KW2
Monthly assessment - Individual representation Month: September 1996
Scope of insp. per product Specified Actual Inspection scope per product Required Actual
-Surfacefin./coat.
-Ident./Stamping
-Edge trimming
- Cold rolled sheet metal (KB) 5 4 - Hot alu. sheet metal (AS) 0 0
-Coil-Inner-
-Coil-Weight
-Auter wind.
-Coil thickn.
-Inner wind.
-Stable side
5 7 0 0
-Weld seam
- Hot galvanized sheet metal (Z) - Coil coated sheet metal (OC)
-Coil status
-Coil edges
-Packaging
-Coil width
-Evenness
-Labelling
5 4 0 0
-Surface
- Galvannealed (ZF) - Other
-Surf.
- El. Galvanized sheet metal (ZE) 5 5
Seq. Dimensions S
Iden No. Pack No. Cust. Prod. Comments*
No. Width Thick. G
1 84405-01 H234535 AUTO 1270 0,70 6 ZF 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 401: color uneven
2 2R643-01 E236492 AUTO 1610 0,75 6 ZE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3 85307-12 G220290 AUTO 1530 0,90 8 Z 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
4 2R591-01 E213971 AUTO 1220 0,80 6 ZE 0 0 0 0 0 0 0 0 0 0 5 0 0 0 0 0 0 0 301: poorly oiled

5 08137-01 F210690 AUTO 1625 0,77 6 Z 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 08111-11 F210672 AUTO 1170 0,90 6 Z 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 201: strong buring on edge trim
7 84421-01 H234591 AUTO 1200 0,75 6 ZF 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 2R766-01 E236594 AUTO 1580 0,75 6 ZE 0 0 0 0 15 0 0 0 0 0 0 0 0 0 0 0 0 0 103: Start of coil 150 m, binding band pressure marks
9 2R388-01 E236608 AUTO 1625 0,75 6 ZE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
10 163873E C239294 AUTO 1600 0,84 6 KB 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 163875E C269300 AUTO 1600 0,84 6 KB 0 0 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 102: Coil edges slightly damaged
12 14770-11 G220565 AUTO 1540 1,20 7 Z 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
13 163800X C269236 AUTO 1805 0,80 8 KB 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 011: Label dirty
14 08110-11 F210669 AUTO 1170 0,90 6 Z 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 402: Occaisional scale
15 84537-01 H234714 AUTO 1200 0,75 6 ZF 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
16 158887E C215741 AUTO 1433 0,80 6 KB 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 404: Medium waviness
17 08494-01 F210906 AUTO 1625 0,77 6 Z 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 401: Stripey surface after grinding
18 84505-01 H234729 AUTO 1600 0,71 6 ZF 0 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 101: Inner 10 windings, 10 mm run off center
19 85974-01 G221059 AUTO 1500 0,60 8 Z 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
20 2S787-01 2S787-01 AUTO 1460 0,80 6 ZE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
*Comment: For every nonconforming evaluated with min. 5 nonconf. points, an action plan with details regarding the cause of the nonconformities and corrective actions must be raised!
Date/Signature
Auditor / Company Inspectors Management / Head of Quality Dept.
Bild 11.2.3: Product audit - Reinspection: Monthly Evaluation
36
Internal Company Reinspection - Monthly Evaluation - September 1996 - KW2
QF-PD de Fries
Ident No.
Non Customer Aggr.
Seq
Conf Dimension SG Delivery Type of nonconformity Cause Immediate action Corrective action Responsible
No.
pts Product insp.
Application
2R766-01
AUTO 103: Start of coil 150m Fine adjusting of the new
Nonconforming length
8 15 1580x0,75 6 IA 2 Binding band pressure Automatic binding machine automatic binding machine Finishing Plant 2
was cut off
ZE marks in Inspection Plant 2
Side part
2R591-01
AUTO Coil was reoiled
Finishing
4 5 1220x0,80 6 EBA 2 301: Poorly oiled Fault in the nozzle beam during the Fitting of flow meters
EBA 2
ZE reinspection
Roof
Bild 11.2.4: Internal Company Reinspection - Monthly Evaluation
37
11.3 Case Example Laser and Mash Seam Welded Tailored
Blanks - Thyssen Stahl AG
The next section describes the planning, performance, and monitoring of

product audits on laser and mash seam welded tailored blanks.
The product quality of tailored blanks, already finally inspected and ready
for dispatch, is checked in random samples for compliance with the
requirements.
11.3.1 Selecting Samples for Inspection
When selecting samples of the blanks to be inspected, the following criteria

are to be especially considered: customer complaints, problem parts, large
lot sizes, high rework and rejection costs, not easily detectable faults,
extremely large measuring uncertainty etc.
The sampling is carried out as a random selection.
11.3.2 Scope of Inspection

From each series checked, the following number of pieces per product are
to be inspected for all important characteristics. The auditor decides which
characteristics will be checked. For characteristics which require a lot of
inspection time, energy and money, the auditor can be satisfied with only a
small number of samples (min. 10 pieces).
A3 plants 50 pieces min.

LRV - plant 10 pieces min
T4 - plant 10 pieces min.
LSA3 - plant 10 pieces min.
11.3.3 Process and Sequence of Operations
1. Take samples of the dispatch-ready tailored blanks to be inspected from

the store or from the final inspection department. The auditor is respon-
sible for their correct return.
2. Obtain all documents, such as drawings, inspection forms, inspection

instructions etc.
38
3. Review the documents with regard to validity, correct revision status.
4. Measure the blanks according to customer drawing (Dimensional

inspection).
5. Visual inspection of the blanks (see Nonconformity Classification).
6. Material testing (if required) to be carried out.
7. Prepare audit report.
8. If the tailored blanks are in perfect condition according to the audit

report, then the inspected samples can be handed back to the
store/dispatch, after they have been preserved and repacked.
11.3.4 Product Audit Report
The measured values are to be statistically analyzed. Cpk-values and

statistical known quantities are to be shown in the audit report.
The results are immediately transmitted to the production department.
A copy of the product audit report is to be distributed to the works manage-

ment, the Head of Production and the quality department.
11.3.5 Procedure for Handling Nonconformities
The nonconformities found during the audit are, depending on the severity
of the fault (Fig. 11-3-5-1) immediately, or daily notified to the involved
areas of responsibility for corrective actions. Immediate corrective actions
are monitored by the quality department in parallel.
Based on the results of the product audit, if necessary, nonconformity

analyses are to be carried out by the production and quality department
and actions to eliminate the cause of the nonconformities are to be
initiated.
Monitoring the effectiveness of the initiated actions lies with the quality
representative of the respective works.
39
11.3.6 Dispatch Audit
At irregular intervals, deliveries ready for dispatch are to be checked accor-

ding to the criteria of the Dispatch Audit Checklist (Fig. 11-3-6-1) prior to
loading.
If nonconformities are found, the dispatch department is to be immediately

informed. They must then initiate immediate corrective actions.
11.3.7 Responsibility
Overall responsibility Works management

Processing responsibility /Auditors Quality dept./Representative
Audit subject Dispatch ready blanks/Deliveries
Determining scope, inspection characteristics Quality Dept.
and samples
Determining the weighting factors for the Quality Dept.
audited characteristics
Raising, maintaining and releasing checklists Quality Dept.
Organizing the inspection procedure and Auditor
sampling blanks
Performing the dimensional inspections Auditor
Performing the material testing Auditor
Preparing audit reports (Nonconformity report/Monthly Auditor
report)
Reporting : Nonconformity report to Production / Quality Dept.
Responsible for carrying out corrective actions Production / Dispatch Dept.
Check of the corrective actions Quality Dept.
40
Product Audit Nonconformity Classification
Major noncon- Nonconformities which can lead to failure/rejection.

formity 1=
Overlay faults, holes in the weld seam, dimensional
nonconformities
Major noncon- Nonconformities which can lead to disruptions in

formity 2= further processing
Stack geometry, oil deposit.
Major noncon- Nonconformities which lead to minor impairments

formity 3= but are not allowed according to the specification
Packaging faults, loosened binding band, pallet beams

out of alignment
Major noncon- Nonconformities which, very likely, will not lead to

formity 4= any disruption and are not specified (cosmetic
faults)
Dirty packaging, bent label, small surface faults, e.g.

light scratches.
Fig. 11-3-5-1: Nonconformity Classifications for Laser and Mash Seam

Welded Tailored Blanks
41
Dispatch Audit Checklist
Dispatch Audit No.:
Tailored Blank Part Number Internal Order Number
TFT Delivery Note No. Customer Reference No. Customer
On ___________ in the store and dispatch dept. ______________ a dispatch audit was carried
out.
Following characteristics were checked and compared to the customer order:

1. Complete customer address with unloading area o
2. Customer reference no. o
3. TFT reference no. o
4. Dispatch details o
5. Dispatch no. o
6. Labeling (Application, Legibility and compliance with o

the customer order)
7. No. of pieces (compliance with the customer order) o
8. Packaging (Required type and marking/identification) o
9. Dispatch papers (compliance with the customer order) o
10. Correct loading onto the forwarders vehicle o
During the dispatch audit the following /no* nonconformities were found:
*please cross non applicable
Fig. 11-3-6-1: Dispatch Audit Checklist Laser and Mash Seam Welded
Tailored Blanks.
42
11.4 Case Example Bearing Bush - AG Khnle, Kopp &
Kausch
11.4.1 Explanation
Systematic Quality Evaluation Production and
Purchasing (SQPP)
The product audit system SQPP (SQFE in German), combines quantitative

and qualitative characteristics, showing them as a quality code number and
allowing a timed assessment and control of quality.
The advantage here is, that these quality numbers can be used as a mana-
gement tool, in order, on the one hand, to identify the improvement
potential of the examined product and, on the other hand, to allow the
comparison of differing products.
To establish the quality code number, the tolerance area of quantitative
characteristics is divided into different zones. The individual zones are allo-
cated a number of minus points, depending on the significance of the
nonconformity they represent.
Categories of minus points according to the following criteria:
Grading Criteria
55 RECALL ACTION NECESSARY
- A failure which results in the destruction of the superior sub-
assembly (Motor, gears, etc.).
15 REWORK UNAVOIDABLE
Unacceptable cosmetic fault which will be identified by every
customer
- Functional failure
Major faults preventing assembly
5 REWORK RECOMMENDED
Cosmetic faults, which are criticized by most customers
- Failure causing customer dissatisfaction
- Fault disturbing assembly
3 - no visible direct impact on function
- however, requires a readjustment of the characteristic to within
tolerance limits
- Cosmetic faults generally accepted by the customer
43
Tu TT To
two-sided characteristic
Tm
10 % 17 % 66 % 17 % 10 %
4 3 2 1 2 3 4
TR
one-sided characteristic
0 limited
83 % 17 % 10 %
TR = Tolerance range
1 2 3 4
Tm = Tolerance mean
Zone 1: 0 Minus points
Zone 2: 3 Minus points
Zone 3 and 4: In this zone 5, 15 or 55 minus points are issued depen-

ding on the severity of the nonconformity.
For qualitative characteristics which are only evaluated according to

Nonconformity found or Nonconformity not found, one proceeds in the
same manner. Depending on the severity of the potential nonconformity,
minus points are assigned.
Example: Minor damage 5 Minus Points

Major damage 15 Minus Points
In the following example, only the large-scale manual calculation method to

establish the code number is described.
44
For the continual application of SQPP, the use of a computer-aided calcu-
lation program is recommended, which, simultaneously allows the audit
planning and statistical analysis to be carried out.
The code numbers are hereby automatically established from the audit
results.
11.4.2 Code Number System for SQPP
a) NNC = Niveau of Nonconformity:
This known quantity is the most important code number and consists of
four digits. This number shows how many characteristics were marked with
55, 15, 5, 3 minus points during the product audit.
Example - Niveau of Nonconformity (NNC NNQ in German)
If the sum of a digit of the NNC is greater than 9, it is set to 9 for formal
reasons.
Characte- n55 n15 n5 n3 NNC

ristic No.
1 0 0 0 0 0000
2 0 1 2 1 0121
3 1 1 0 0 1100
4 0 0 0 5 0005
5 0 0 0 1 0001
1213
Explanation: 1 Characteristic has a minimum of a 55-Points-Nonconformity

2 Characteristics have a minimum of a 15-Points-Nonconformity
1 Characteristic has a minimum of a 5-Points-Nonconformity
3 Characteristics have a minimum of a 3-Points-Nonconformity
n = number of nonconformities in the respective negative points
category
45
b) QCC = Quality-Capability-Coefficient
The Quality-Capability-Coefficient (QCC CAQ in German) is a code

number for variable characteristics. It shows what percentage of a
tolerance area related to the tolerance mean is used. The smaller the QCC,
the stronger the measured values are focused around the tolerance mean.
If the QCC = 1, the measured values lie at the tolerance limit (in this case,
the QCC is set to 0.99 for formal reasons).
two-sided tolerance range = Maximum of:
max-value - Tm Tm - min-value
or
TR/2 TR/2
one-sided Tolerance area = max-value

0 limited TR
Tm = Tolerance mean
TR = Tolerance Range
The QCCmax is the largest QCC across all characteristics.
c) NDQ = Niveau of the Delivery Quality:
The NDQ supplements the NNC by the maximum used tolerance of a

characteristic.
NDQ = NNC + QCCmax
d) Av = Average Minus Points:
A value that is monitored over a period of time, is the average minus points
per product.
A comparison of this value over time is only acceptable, if it concerns the

same product and the number of characteristics has not changed.
46
The Av is the sum of the realized mean quality numbers, Amr, per
characteristic.
Ar (55xn55)+(15xn15)+(5xn5)+(3xn3)
Amr = = Ar = realized Q-number
m m = Sample size per characteristic
n3/n5/n15/n55 = Number of assessment results falling into the

respective minus points categories.
11.4.3 Procedure using Bearing Bush as an Example
Step 1: Determine the characteristics to be assessed, inspection,

measuring and test equipment and frequency .
4 2
Step 2: Allocate the minus points per characteristic (see

Appendix)
Step 3: Assessment of 20 Parts Minus Point Categories
variable: 1.) Length 5

2.) Inside diameter 15
3.) Surface roughness 15
attributive: 4.) Outside diameter 5

5.) Damage 5
47
Step 4: Evaluating the Measured Results (m = 20)
Characte- 20.5210 20.4880 Characte- 8.4010 8.3970

ristsic1 ristsic2
20.5280 20.5000 8.4020 8.4040
20.5190 20.5060 8.4050 8.4010
20.5060 20.5010 8.3950 8.3970
20.5010 20.4850 8.3990 8.4050
20.5110 20.5250 8.4000 8.4000
20.5020 20.5170 8.3920 8.3970
20.5190 20.4820 8.3920 8.3950
20.5290 20.4990 8.4010 8.4010
20.5450 20.4900 8.3980 8.4030
Characte- 1.9800 1.8000

ristsic3
1.7200 1.9200
2.2100 1.8700
2.0100 2.1000
1.9900 2.0400
1.9000 2.0100
2.1500 1.9900
2.1900 1.7900
2.2400 2.2200
1.6700 1.9700
Characteristic 4 20 x O.K.
Characteristic 5 20 x O.K.
48
Step 5: Calculation
5.1) Calculation of Ar, Amr and Av
Ar
No. Characteristic Ar = realized Q-Number Amr = Amr
per characteristic m
1 Total Length 0 + 0 + 0 + 1 x 3 3 0,15
20
2 Inside diameter 0 + 0 + 0 + 2 x 3 6 0,3
20
3 Surface roughness 0 + 0 + 0 + 0 0 0
4 Outside diameter 0 + 0 + 0 0 0
5 Damage 0 + 0 + 0 0 0
Av = 0,15 + 0,3 = 0,45
5.2) Calculation of NNC
No. Characteristic n 55 n 15 n 5 n3 NNC
1 Total Length 0 0 0 1 0 0 0 1
2 Inside diameter
0 0 0 2 0 0 0 2
3 Surface roughness
0 0 0 0 0 0 0 0
4 Outside diameter
0 0 0 0 0 0 0
5 Damage 0 0 0 0 0 0 0
=> NNC= 0002
49
5.3) Calculation of QCC and NDQ
Two-sided tolerance
No Characteristic min. max. Tm - min max-Tm QCC

QCC= QCC=
TR / 2 TR / 2
20,5 - 20,482 20,545 - 20,5

Total Length 0,05 0,05
1
20,5 0,05 20,482 20,545 = 0,36 = 0,90 0,90
Inside 8,4 - 8,392 8,405 - 8,4

2 diameter 8,4 8,392 8,405 0,01 0,01
0,01
= 0,80 0,50 0,80
One-sided tolerance
No Characteristic min. max. max-Tm QCC

QCC=
TR / 2
Surface 2,24 0,56

3 roughness Rz 1,67 2,24 4,0
4,0
NDQ = NNC + QCCmax

=> QCC max = 0,90
=> NDQ=0002,90
50
Computer-aided Evaluation
Aktiengesellschaft
Khnle, Kopp & Kausch
Evaluation Form SQPP
Marnheimer Strae 85/87
67292 Kirchheimbolanden
Commission-No.: 7000 1000
Machine-No.: 133 0000 Customer:
No of pieces: 20 Work process: Component
Description: Bearing Bush Responsible department:
Part-No.: 5315 100 2000 - Date: Signature:
P Description of characteristic 55 15 5 3 0 3 5 15 55
1 Total Length - - 0 0 19 1 0 - -
Inspected number : 20
(Height measuring gauge) AMR = 0,15
quantitative QCC = 0,90
Specified value: 20,5000
upper tolerance: 0,0500
lower tolerance: 0,0500
2 Inside diameter - 0 0 2 18 0 0 0 -
quantitative --> Nozzle gauge AMR = 0,30
QCC = 0,80
3 Surface roughness - - - - 20 0 0 0 -
quantitative --> Measurement of surface AMR = 0,00
roughness QCC = 0,56

4 Outside diameter - - - - 20 - 0 - -
qualitative--> snap gauge
5 Damage - - - - 20 - 0 - -
Inspected number: 20
qualitative --> Visual
Total Evaluation SQPP
NNC = 2 NDQ = 0002,9 Av= 0,45 QCCmax = 0,90
51
Documentation
If quality deviations or nonconformities are found (NDQ 10), immediate

corrective action must be taken.
Parts No.: 5315 100 2000 Comm.-No.: 7000 100.0

Work process: Component No. of pieces: 20
Description: Bearing bush Responsible department:
Mash.-No.: 133 0000 Date: 27.05.1996
Signature:
__
Av NQ + QCCmax
0,45 0002,9
25 Du 9999 NNC
5000
20 1000
500
15 100
50
10 10
5 X
X
5 1 X X X
X
X X X 0,5
0 X Month 0 Month
JFMAMJJASOND JFMAMJJASOND
/ /
A A
Distribution: Date: Signature
27.05.1996
52
K
K K
Aktiengesellschaft
Khnle, Kopp & Kausch
Parts-No..: 5315 100 2000 Mach.-No.: Parts-No.: 5315 100 2000 Month 1
Work Process :Component Date: 27.05.96 Signature.: ______________ Comm.-No.: 7000 100.0
No. of pieces: 20 May 96
Benennung: Lagerbuchse Responsible Department.: AQI
Characteristics Inspection, Units Summary of 55 15 5 3

NC measuring and exa- characteristics 0 0 0 2
mined
Test Equipment
Dmr 55 15 5 3 CAQ
5 3 -0- 3 5
1 Total Length quantitative 20
20,5 0,05 Micro-Hite 19 1 0,15 0 0 0 1 0,9
20,450 20,467 20,533 20,550

15 5 3 -0- 3 5 15
2 Inside diameter quantitativ 20
0,30 0 0 0 2 0,8
8,4 0,01 barrel gauge 2 18
8,389 8,39 8,3934 8,4066 8,41 8,411
-0- 3 5 15
Surface quantitativ
3 roughness surface roughness 20 0 0 0 0 0 0,56
20
measuring
equipment 3,32 4,0 4,4
-0- 5
4 Outside diameter qualitaiv 20 20 0 0 0 0 0 0
snap gauge
-0- 5
5 Damage qualitativ 20
visual 0 0 0 0 0 0
20
Issue/Revision Subtotal of the 55 15 5 3 CAQ 0,9

Name characteristics max
Date 55 15 5 3
Total sum of the NNQ 0 0 0 2 Du 0,45 NQL 2 , 9 0
Signature characteristics 0 0 0 2
53
11.5 Case Example Valves - TRW Deutschland GmbH, Motor
Components
Explanation
A minimum of 50 valves ready for dispatch are taken from storage and
subjected to a product audit. Design drawings, inspection instructions and
quality guidelines from the basis of the evaluation. The basic
characteristics defined in the quality guidelines are measured to the
drawing and statistically analyzed. Visual nonconformities, such as impact
marks, grinding marks, scratches, material defect marks or pores, are
inspected using a nonconformity catalogue and, depending on their
functional impairment, differentiated into major and minor nonconformities.
Major nonconformities are deviations from design drawings which can lead
to impairment of the valve function in the motor.
The results are documented in the audit report, where type and frequency
of the found nonconformities are explicitly presented.
If faulty parts are found, the quality control management is informed imme-
diately. For minor nonconformities, it is then decided if the part will be
reworked or a concession which must be approved in writing by the
customer. For major nonconformities which impair function, stock is in the
store is placed on hold and is subjected to a 100 % reinspection with
regards to the nonconformity characteristics found.
Based on product audit results, nonconformity analyses are carried out for
nonconformities where the cause is unknown and actions to prevent
recurrence are introduced. The quality representative is responsible for
monitoring the effectiveness of the introduced actions.
The main reason for carrying out the product audit, however, is to establish
the quality niveau of the delivered valves. Hereby, the statistical analyses
and their statement to the process capability of the variable main
characteristics, are significant.
54
TRW Deutschland GmbH
Motor Components
Postfach 11 11, 30881 Barsinghausen
Product Audit Report-No. 501.929.016.96 Date: 09.09.1996
Pages:
3
A product audit was carried out on exhaust valves ready for Attachments:
dispatch, destined for company........ .
2 Statistic tables
Drawing-No.: 076.029.200.01.2 Customer: . . .. Processor:

Order-No. 80174-00 Customer-Ref. No. 90 289 198
VCQ / Tel.350
Summary
After final inspection, 100 valves with the Ref. No. 076.029.200.01.2 were
taken as samples.
The parts were manufactured in production line No. 3.

During visual inspection, 3 major nonconformities and 2 minor nonconfor-
mities were found.
During dimensional inspection, 13 characteristics were inspected of which 2
did not reach the required minimum capability index.
Individual Result/Visual Inspection Nonconformity

weighting
1 Defect mark on the seat > 0,5 1

1 Impact mark on the seat (raised < 0,5) 2
1 Impact mark on the seat (not raised > 0,5) 2
2 Impact marks in the throat (not raised > 0,5) 3
55
Individual Result/Dimensional Inspection
The following characteristics lie below the required index of 1,33
Cp-Value Cpk- Value P- Value Pe- Value
Plate edge height 1,24 0,73 0,00% 1,287%

Seat angle 1,37 1,30 0,00% 0,005%
For a detailed listing see Appendix.
Note: Quality control was informed immediately.
Distribution: Auditor: inspected:

G, M, T, TQ, VC, VP, VPQ 2x, VCQ
56
Table to Product Audit No.: 501.929.106.96
Character. Plate Shaft Shaft Insert Insert Seat Plate edge Seat concentr.
valve head shaft side shaft end shaft end height
Meas. unit mm mm mm mm mm mm mm mm
Spec. size 31,00,15 6,9850,007 6,9850,007 4,080,07 5,80,1 103,00,15 2,00,2 max 0,03
n 100 100 100 100 100 100 100 100
ULV 31,15 6,992 6,992 4,15 5,90 103,15 2,20 0,03
LLV 30,85 6,978 6,978 4,01 5,70 102,85 1,80 0,00
Max. x 31,069 6,984 6,986 4,081 5,796 103,055 2,191 0,018
Min. x 30,929 6,981 6,980 4,045 5,751 102,908 1,915 0,000
Cp 1,77 4,04 2,00 3,44 3,42 1,52 1,24 -----
Cpk 1,63 2,43 1,43 2,92 2,50 1,46 0,73 2,66
P% 0,00% 0,00% 0,00% 0,00% 0,00% 0,00% 0,00% 0,00%
Pe % 0,00% 0,00% 0,00% 0,00% 0,00% 0,00% 1,287% 0,00%
x-3s 30,9038 6,9805 6,9794 4,0488 5,7438 102,8982 1,9226 -----
x 30,9878 6,9822 6,9830 4,0695 5,7732 102,9936 2,0816 0,0056
x + 3s 31,0718 6,9839 6,9866 4,0902 5,8026 103,0890 2,2406 0,0149
P% = Nonconforming parts in %
Pe % = % of Nonconformity to be expected statistically
57
Table to Product Audit No.: 501.929.106.96 (Continued)
Character Seat Seat angle Surface Surface Surface

roundness roughness roughness roughness
Seat Ra Shaft Ra Mirrors Ra
Measuring
m Deg. Min m m m
unit
Spec. size max.6.0 44 07 max 0,5 max 0,2 max 0,4
n 30 30 30 30 30
ULV 6.0 44 07 0,5 0,2 0,4
LLV 0.0 43 53 0,0 0.0 0.0
Max. x 2,1 44 03 0,369 0,119 0,229
Min. x 0,9 43 57 0,175 0,078 0,049
Cp ----- 1,37 ---- ---- ----
Cpk 4,41 1,30 1,73 4,91 3,46
P% 0,00% 0,00% 0,00% 0,00% 0,00%
Pe % 0,00% 0,005% 0,00% 0,00% 0,00%
x-3s ----- 43 55 ---- ---- ----
x 1,4400 44 00 0,2604 0,0872 0,0707
x + 3s 2,4690 44 05 0,3989 0,1102 0,1658
P% = Nonconforming parts in %
Pe % = % of Nonconformity to be expected statistically
58
11.6 Case Example Tires - Continental AG
Explanations : Extracts from the procedure
11.6.1 Scope and Frequency of Inspection
The tires to be inspected are taken from current production. There is a

choice of various designs under consideration of
- the number of production pieces manufactured

- if applicable, varying customer requirements.
Tires from the store of the factory or - if not available - from the final
inspection point (after completion of inspection has been completed) are to
be examined.
A minimum of 250 tires are to be examined, split across five or six differing
designs. All tires are to be assessed visually. For two designs, the folowing
additional tests are to be carried out:
True running Unbalance X-ray examination
The product audit is to be carried out once a year.
11.6.2 Specifications, Inspection, Measuring and Test

Methods
The same nonconformity catalogs and limit values apply as during final
inspection of the tires. When checking the true running and unbalance, the
measuring tolerance is also to be considered.
The measurements are to be taken using the same testing machines as in

the series.
59
11.6.3 Process
11.6.3.1 Auditor
The auditor is generally sent by the Quality Assurance Department. Trained

auditors from other tire factories are also acceptable.
11.6.3.2 Visual Inspection
The visual inspection is carried out by the auditor himself.
11.6.3.3 Machine Tests
The machine tests are carried out by the respective operators in the
presence of the auditor.
11.6.4 Documentation
The inspection, measuring and test results are recorded on forms and com-
piled into an audit report. The overall result is followed over a period of
time.
11.6.5 Evaluation
During a product audit, no tires which exceed limit values or deviate from
limit patterns should be found as a major nonconformance. Otherwise,
immediate corrective actions, planned for such an instance, must be
initiated.
11.6.6 Forms
11.6.6.1 Visual Inspection
11.6.6.2 Concentricity
60
QUALITY SPEZIFICATION
Aktiengesellschaft
PRODUCT AUDIT Plant: XXXX
Tires off-standard for visual inspection Date: 29. 05. 96
SIZE 4731 981 311 845
Off-standard tire category 1 2 3 1 2 3 1 2 3 1 2 3
Numbers of tires inspected 50 50 45 60
Tires on-standard
Blisters sidewall
tread/belt
miscellaneous
Rubber folds sidewall
miscellaneous
Lack of material sidewall
bead
miscellaneous
Bead condition
Foreign matter (rubber in bead seat)
Off-standard tires bladder

from curing miscellaneous
Circumferential flash 1
Lettering illegible or incomplete
Poor repair
Poor trimming
Grinding too severe

not clean
Dirty mold
tire
Inspector's stamp missing
illegible
Total off-standard tires units 1 0
% 2,0 0,0
Remarks: No made conformity
CONTINENTAL GROUP QUALITY CONTROL BOOK: 0.0

PLANT QUALITY AUDIT SYSTEM
MC: Date: 01.06.92 PAGE: ISSUE: 5
61
QUALITY SPEZIFICATION
Aktiengesellschaft
PRODUCT AUDIT Plant: XXXX
Uniformity Passenger Date: 29. 05. 96
SIZE: 981 Conicity (CON) (daN)

more than 13.0
n= 50
12.1 - 13.0
11.1 - 12.0
Radial Force Variation (RFV) (daN) 10.1 - 11.0
9.1 - 10.0
more than 20.0 8.1 - 9.0
19.1 - 20.0 7.1 - 8.0
18.1 - 19.0 6.1 - 7.0
17.1 - 18.0 5.1 - 6.0
16.1 - 17.0 4.1 - 5.0 I
15.1 - 16.0 3.1 - 4.0 IIIII
14.1 - 15.0 2.1 - 3.0 IIIII III
13.1 - 14.0 1.1 - 2.0 IIIII IIII
12.1 - 13.0 0.1 - 1.0 IIIII IIIII
11.1 - 12.0 -0.9 - 0.0 IIIII III
10.1 - 11.0 -1.9 - 1.0
9.1 - 10.0 -2.9 - 2.0
8.1 - 9.0 I -3.9 - 3.0
7.1 - 8.0 IIIII II -4.9 - 4.0
6.1 - 7.0 IIIII IIIII III -5.9 - 5.0
5.1 - 6.0 IIIII IIIII II -6.9 - 6.0
4.1 - 5.0 IIIII IIIII I -7.9 - 7.0
3.1 - 4.0 IIIII -8.9 - 8.0
2.1 - 3.0 I -9.9 - 9.0
1.1 - 2.0 -10.9 - 10.0
0.1 - 1.0 more than -11.0
1st. Harmonic (RFH) (daN) Lateral Force Variation (LFV) (daN)
more than 15.0 more than 15.0
14.1 - 15.0 14.1 - 15.0
13.1 - 14.0 13.1 - 14.0
12.1 - 13.0 12.1 - 13.0
11.1 - 12.0 11.1 - 12.0
10.1 - 11.0 10.1 - 11.0
9.1 - 10.0 9.1 - 10.0
8.1 - 9.0 8.1 - 9.0
7.1 - 8.0 7.1 - 8.0
6.1 - 7.0 6.1 - 7.0
5.1 - 6.0 III 5.1 - 6.0 II
4.1 - 5.0 IIIII IIIII II 4.1 - 5.0 IIIII IIIII
3.1 - 4.0 IIIII IIIII III 3.1 - 4.0 IIIII IIIII IIII
2.1 - 3.0 IIIII IIIII III 2.1 - 3.0 IIIII IIIII III
1.1 - 2.0 IIIII III 1.1 - 2.0 IIIII IIIII I
0.1 - 1.0 I 0.1 - 1.0
CONTINENTAL GROUP QUALITY CONTROL BOOK: 0.0

PLANT QUALITY AUDIT SYSTEM
MC: Date: 01.06.92 PAGE: ISSUE: 3
62
11.7 Case Example Complete Vehicle - FORD AG
Explanations:
11.7.1 Check of Conformity
A conformity review is a special type of product audit and serves as

evidence for the manufacturer of complying with legal requirements
towards authorizing agencies.
The example shown, deals with the compliance of built parts with approved
components listed in the system approval and approved by the applicable
authorizing authority (in Germany, this is the Kraftfahrt Bundesamt [KBA]).
The underlying legal requirement is a directive of the European

Commission 70/157/EC Extraneous Noise in the annex 96/20/EC.
11.7.2 Complete Vehicle
The examination of vehicles is carried out with the help of a checklist,

whereby the user may decide on the scope with regards to nonconformity
locations and types. The list can be customer, as well as production
orientated. The outline of the checklist determines the sequence of the
checks.
The presented checklist can be used for a product audit of the

manufacturer, as well as dealer.
The evaluation of a product audit on complete vehicles should usefully be

carried out using an EDP program, taking into account the complexity of
vehicles.
A coding system for parts, nonconformity locations and types serves those
organizational areas which receive necessary information from it.
63
The use of the same terms for nonconformity locations and types serves
organizational areas (e.g. customer services, warranty department, quality
assurance, design and development) in continual product improvement of
current and future models.
The inspector / auditor indicates the found nonconformities in the checklist

and explains the causes for complaint in the corresponding space provided.
A nonconformity weighting can take place in the form of a points system,

that reflects the share of customers who complain about this nonconformity
(e.g. 90%, 50%, 10%, 1%). Other evaluation criteria are also possible.
The evaluation can take place in the form of
- a Pareto-Analysis to clearly present the nonconformity focal

points or
- a comparison with the previous month (first possibility to esti-
mate the effectiveness of introduced corrective actions
possible).
Furthermore, separate evaluation of individual production areas like press

works/shell construction, coating, final assembly and others (suppliers etc.)
is helpful when trying to find the cause of a problem.
All evaluation examples can take place on the basis of differing time
periods, daily, weekly, monthly or yearly. Longer evaluation periods serve
the verification of corrective actions carried out.
64
QUALITY CONTROL CONFORMITY NOISE LEVELS Page 1 of 1
LEGAL
Issue: 17.10.95
REQUIREMENTS PART INTEGRITY TEST
Revised: 28.05.96
MODEL: Country Code:
Approval: e13*70/157*96/20*4573*02
Vehicle type:
Chassis-No.: * W F 0 0 X X J *
Version: AJS 5-Door Sedan CJS 5-Door St Wagon
BJS 3-Door Sedan DJS 3-Door St Wagon
ENGINE: Petrol Motor Code : H W A

Cubic capacity : 1298 cm3 Output: 65 kW
GEAR: MANUAL AUTOMATIC
Transmission ratio : 4.27 3.84
Gear marking :
CATALYTIC CONVERTER FITTED

MUFFLER
FRONT :
MIDDLE : 1 0 5 2 9 2 2 4 10629328
REAR : 1 0 5 2 9 2 3 7
AIR FILTER: 78896433
TIRES: Tread radius -upper/lower limit Tires acc. to WVTA approval
Axle 1 / Axle 2 266 / 266 mm 155/70 R13

Axle 1 / Axle 2 264 / 264 mm 165/65 R13
Axle 1 / Axle 2 272 / 272 mm 185/70 R13
Axle 1 / Axle 2 269 / 269 mm 165/65 R14
Axle 1 / Axle 2 274 / 274 mm 185/55 R14
NOISE REDUCTION: Engine hood Cowl top inside

Engine cladding Cowl top outside
Gear cladding Cowl bottom outside
Inspection result:
Vehicle complies with the details listed in the approval and above:
YES NO
Date: Name: Signature:
Legend : 4 = to be noted for ok or deviation = complete as necessary = Change
65
Model: Chassis Number: Engine Code:
Variant: Country Code:
Part 1: Lighting, Instruments and Controls
Part 1 of the form contains functional tests regarding lighting, instruments

and controls. Each position shown in the drawing is to be checked and
marked in the corresponding box - " " = O.K. or " X " when a repair or
correction is necessary. Further details regarding the repair/correction are
to be entered in the fields below.
Function Lighting, Instruments and Controls
High Series shown; Deviations possible not built-in or in different position

in other variants
Seq. No. Description Eliminated
66
Funktion Beleuchtung, Instrumente und Kontrollanzeigen
Console upper Window winder

Lighting and switch, mechanism; Window
Mirror locks and catch hooks
at side and rear
Sun shades Seat adjustment
Side mirrors Safety belt - front:

Check belt for
cleanliness and twists
Light switch: Door light switch

Headlights, Side
lights
Multifunctional- Door locks; incl.

switch: side sliding door and
rear door or tailgate
Windshield wipers
and washer
Multifunctional - Safety belt rear :

switch: Horn,
Headlights Check belt for clean-
and Indicators liness and twists
Headlight Passenger seats

washer
Windshield washer Inside lights

(front and back)
Windshield wipers
(front and back)
Seq. No. Description Eliminated
67
Part 2: Mechanics and Road Test
Part 2 of the form contains checks of the mechanical functions and the
road test. Each shown position is to be checked and marked in the corres-
ponding box - = O.K. or X when a repair or correction is necessary.
Further details regarding the repair/correction are to be entered in the fields
below.
Mechanics
O.K. Repair Repair
O.K.
Battery charge status (recharge at 12,4 V or less)
Cold start/Cold start system and control indication (Diesel)
Vehicle underside
Brake hoses / Brake lines - Leakage, damage or chafing
Steering /Suspension connection./Ball and socket joint and collar - Damage/Safety
Exhaust system - Leakage, damage and safety
Electrical system (cables) - Safety, chafing and correct wiring
Electrical connections - Damage, engagement and safety
Leakage Engine oil
Coolant
Gear lubrication / fluid
Steering /Power steering
Suspension
Brake fluid
Fuel lines and tank
Axle oil
Vehicle exterior
Tires incl. spare tire - Damage, correct size and air pressure
Doors, engine hood, trunk/tailgate Adjustment and fitting
Headlights Adjustment
Engine space/trunk/loading space

Engine hood - Unlatching, Lock and catch hooks
Engine space Signs of leakage /condition of the hoses
Engine oil
Coolant
Power steering fluid
Brake fluid
Fuel
Vacuum hoses, incl. vacuum pump (only Diesel)
Turbo supercharger Oil lines / hoses (only Turbo Diesel)
Check and fill up Engine oil
Brake fluid
Coolant (Check antifreeze correct if leaking)
Power steering fluid
Washer water container
68
Part 2: Mechanics and Road Test
Road Test
Ensure that the vehicle is tested under differing conditions and over
different terrain; including hills, flat, even and uneven streets and different
road surfaces. Consider the conditions on town and country roads; pay
attention to any extreme and unusual noises, as well as vehicle reactions.
Road test includes functional O.K. Repair Repair

testing of : O.K.
P/N Start
Accelerator pedal acceleration
Clutch and gear changes
Handbrake
Foot Brake
Gear shifting and Kickdown (Automatic Gear)
Steering / Power steering
Temperature gauge
Fuel gauge
Speedometer / Tachometer
Engine performance
Unacceptable noises Rattling / Screeching
Vibrations
Wind noises
Mechanical noises
Heating and operating control
Smoke development - visual (Diesel)
Further appliances
After road test

Warm start
Automatic gear, oil level - check and fill up (engine warm)
Adjust clock, enter radio code, check audio system, tune in local radio stations
69
Part 3: Vehicle Appearance
Part 3 of the form contains checks regarding the interior and exterior visual
appearance. Each shown position is to be checked and marked in the
corresponding box - = O.K. or X when a repair or correction is
necessary. Further details regarding the repair / correction are to be
entered in the fields below.
Damages / Condition
Damages / Condition O.K. Repair Repair
O.K.
Exterior Damages / condition of paint work, metal and trim
Interior - Damages / condition of trim and upholstery
Interior Water leakage
Carpet Laying, fit and fastening
Loading space door/tailgate fastening, fit and correct closing
Window panes Damages and fit
Tools available and complete
Vehicle keys complete and function in ignition, doors and fuel cap
Mark every found nonconformity with an " X " and a sequential number at
the corresponding point on the drawing. Nonconformities and corrective
actions are to be entered on the back page of this sheet using the
sequential number.
Vehicle exterior
70
Part 3 : Vehicle Appearance
Mark every found nonconformity with an " X " and a sequential number at
the corresponding point on the drawing. Nonconformities and corrective
actions are to be entered at the bottom of this sheet using the seq. number.
Vehicle interior
Part Affected Description Corrective Action Eliminated
10
71
11.8 Case Example Complete Vehicle - Volkswagen AG
The product audit for finished vehicles (Vehicle audit) serves to identify
delivery quality and is carried out at car manufacturers on vehicles ready
for delivery.
It is orientated, on the one hand, to the buyers requirements, including

those wishes not specifically expressed by the customer (such as, e.g.
being waterproof). On the other hand, the results of the vehicle audit serve
to recognize all nonconformities possible to identify and to initiate
improvements for the benefit of the customer.
The delivery quality is represented using a code number, the quality

category (QC). It is the sum of the nonconformity points of a vehicle. The
code number is thereby independent of the productive possibilities and
conditions within a works and irrespective of the type of vehicle produced
(passenger vehicles or trucks).
It has proven useful in practice, that the quality category system is

orientated to the school grading system. Grades up to 7,0 are awarded.
Thereby, it is possible that newly developed vehicles can be audited,
additionally to auditing of the current series.
Independent vehicle auditors are appointed to carry out the audits using an
audit guideline describing the scale and procedure of the audit. The
uniform use of the guideline is ensured by annual comparisons.
The sample size per works is up to 1% of the daily production.
The audit process is determined by the sequence in the checklist. A single

checklist is used for all vehicle types, in order to ensure the comparability
of the audit results. It includes the following:
- Engine space/vehicle underside check (as preparation to the

test drive)
- Check headlight adjustment
- Test drive
- Engine space / vehicle underside check (Recheck)
- Check of waterproofing
- Assessment of the electronics, interior fittings, car body
- Assessment of the surface finish.
72
With the exception of the headlight adjustment check, no other measuring
checks are made during the course of the vehicle audit.
If the auditor discovers nonconformities, these are recorded according to

type and location, severity of the characteristic (S = severe, M = medium,
L = light) and for surface finishes, according to zones (e.g. Zone 1
especially high grade).
After evaluation of the checklist, the audit results are regularly presented to
the management and subsequently documented in the form of an audit
report.
Attached is an example audit report of an audited vehicle. This was raised

using :
- the audit checklist

- the weighting / evaluation (A, B or C-Nonconformities) and
- curve to differentiate the quality category
Despite the simple evaluation method and graphic clarity of the quality
category, the used grading system also has disadvantages in practice:
- The grade"-differences in the direction of poorer quality for

equal steps in the points, get smaller so that the true
deterioration is watered down (Reason: Exponential function of
the differentiation curve).
- For new production runs, the quality improvement, important

for the production, is not always clearly recognizable. This can
have a negative influence on employee motivation
73
AUDIT - CHECKLIST Page
7
to 38
Nonconformity type/Weighting (S = Severe, M = Medium, L = Light)
Surface Finish Motor/Engine Test drive Water-
proofing
Nonconformity extrem Missing Incorrect Noises
noncon- Bulge / Scrat- com- compo- Dama- when Extreme Water
Code formity Dent ches ......... ponent nent ged ......... Sluggish driving ......... leakage leakage
Bumper front STF1A S L/S L/S
Zone 1
Front wing Zone 1 FKL1A S L/S L/S
.........
Cooling system MKU10 S S S
- Piping MKU14 S S S
-cooling system
- Heating pulley MKU15 S S S
.........
A-Post cladding DAP11 L/S L/M
left top /S
Exhaust system MOT80 L/S L/M
/S
Glove compartment HAK10 L/S L/M
/S
.........
Rear left window SSH31 S L/S
Left front window SSH11 S L/S
.........
74
Weighting / Evaluation
Nonconformity points > 100 90 70 60 50 40 30 20 10
Nonconformity A-Nonconformance B-Nonconformance C-Nonconformance

evaluation
Safety risk, not acceptable, will unpleasant, disturbing, complaint is to be requires improvement,
sluggish certainly lead to cus- expected, quality nonconformity present complaints from de-
vehicle, tomer complaints, manding customers are
breakdown extreme surface finish to be expected, quality
vehicle nonconformity requirements are not
fulfilled
Effect on/reaktion Vehicle Vehicle must make an Customer will have the nonconformity corrected Customer partially
of the customern not unscheduled visit to the at the next planned visit ti the workshop expects a correction of
available workshop the nonconformity
Detectable by all customers
by demanding customers and trained auditors under consideration of the internal

quality requirements
Correction of the Nonconformities to this extent must be corrected; ensure that no vehicle with this
nonconformity nonconformity reaches the customer
75
76
AUDIT-REPORT
Type: A3 Market: USA Doors: 4 Assembly line: 2 Team: K

Prod. date: 08.02.96 Insp. date: 20.03.96 Inspector: 005
Chassis No.: 1HTM009903 Color: Silver metallic
Engine: 2.0 l Special extras: Sliding sun roof Gear: MQ
Required Actual
Quality category: 1.5 3.4
Points: 523 1390
Weighting of nonconformities A B C
No. of nonconformities : 3 1 90
Points per nonconformity category : 230 40 1120
Nonconformity points per main group :

1. Electronics 90
2. Car body interior 180
3. Car body exterior 280
4. Surface finish 730
5. Engine/Gear 0
6. Test drive 40
7. Waterproofing 70
Individual Results
Nonconf location Nonconf type Comment Responsible Nonconf. pts./cat.
1. Electronics
Right rear light Assembly not satis. Cable bushing T 10 C
Left fog light Assembly not satis. Not working A 70 A
...........................
2. Car Body interior

A-Post Assembly Fit not satisfactory T 10 C
Cladding left top not satisfactory
AIRBAG Assembly Damaged A 40 B
Cover/ Strip not satisfactory
Sheathing inside Dirty R 30 C
back right winding window
...........................
77
Nonconf location Nonconf type Comment Responsible Nonconf. pts./cat.
3. Car body exterior

Left front door Fit not satisfactory B 10 C
Protection strip Color difference V 30 C
left front door
Left front window Operating - Squeaks R 30 C
noise
...........................
4. Surface finish
Front wing Zone I Paint inclusions P 10 C
Front wing Zone III Painting Paint run P 10 C
nonconformity
Left front wing Zone I Extreme surface Paint rip B 90 A
nonconformity
A-post left Zone I Dirty Paint mark P 20 C
seal
Roof (car) Zone I Dent/Bulge B 30 C
...........................
5. Engine/Gear
...........................
6. Test drive
Tailgate Noise when driving Rattles T 10 C
Selector plate Noise when driving Crackles R 30 C
...........................
7. Waterproofing
Tailgate Water leakage Bushing T 70 A
78
11.9 Example of a Product Audit Procedure
- Mercedes Benz AG, Hamburg Works
11.9.1 Purpose
Determining the responsibilities and processes during a product audit.
11.9.2 Scope
Mercedes-Benz AG, Hamburg Works
11.9.3 Terms and Definitions
11.9.3.1 Product Audit
The product audit evaluates in a random sample the product quality of

finally-inspected, ready for dispatch aggregates, with respect to their
compliance with objectives from development, quality assurance, planning,
legislation and customer expectations.
The effectiveness of previous quality actions is assessed through the

product audit, or respectively, the quality niveau of the production process
is established.
WM Works Management
PRD Production
QA Quality Assurance
QMT Quality Assurance Measuring Technology
QWT Quality Assurance Material Technology
DSP Development, Sales and Purchasing
A Audit
79
11.9.4 Responsibilities
11.9.4.1 Product Audit
Overall responsibility Head of QA
Responsibility for performance Head of QA / Audit representative
Audit object aggregates ready for dispatch
Auditors employees assigned with auditing
Establish aggregates, inspection characteristics and Audit

number of random samples
Establish weighting factors for the audit characteristics Audit
Raising and amending checklists Audit
Release raised or amended checklists Head of QA / Audit representative
Sampling of the aggregates and organization of the Auditor

inspection procedure
Carrying out of dimensional checks Auditor, (QMT if required)
Carrying out of material tests QMT
Writing of audit reports (Nonconformity report/Monthly Auditor / QA/Audit

report)
Reporting: Nonconformity report to go to the person responsible for

the audited aggregates
Monthly report to go to WM, PRD, QA, EVE
Responsible for performance of corrective actions Cost center of the audited

aggregate
Controlling of corrective actions Auditor, through audits in rotation
80
11.9.5 Description
11.9.5.1 Performing the Product Audit
The selection and determination of the random sample size and sampling
frequency of the aggregate is to be assessed is carried out with the aim, to
effectively identify the quality status of manufactured aggregates and, so
far as necessary, to introduce corrective actions.
The aggregates are taken as samples by the audit department from the
production area, after final inspection/the last work process, without prior
notice.
The subsequent audit of the aggregates is carried out using a checklist.
This includes all characteristics to be audited and evaluated.
Following inspections are carried out on the aggregates, amongst others:
- visual and functional

- dimensional
- torque
- electrical
- material testing (if required)
Nonconformities found during the audit, are, depending on their severity,

reported to each involved department immediately or daily for correction.
Necessary immediate actions to eliminate nonconformities are monitored
in parallel by the Quality Assurance Department. (see also flow chart of the
product audit process).
The quality evaluation summarizing the audited aggregate is presented in

the form of a quality number (QN). The QN is obtained by taking the identi-
fied nonconformities and their weightings from the checklist and applying a
given calculation within the EDP-aided product audit system. The QN is
announced monthly for the aggregates.
81
The documenting of the audit results is carried out within the EDP-aided
product audit system. A report is raised for each product audit carried out.
Each month, a summary audit report about the audited aggregates is
issued to the works management and responsible heads of department.
11.9.5.2 Product Audit Plan
In the product audit plan, all aggregates to be audited, the random sample
size and sampling frequency are identified. Urgent quality problems are
acted upon immediately.
The audit plan is reviewed annually. New aggregates can be included in

the product audit at any time.
The product audit plan, currently applicable, is always on display in the

audit area.
11.9.6 Additional Notes
11.9.7 Applicable Documents
- Product Audit Plan for Aggregates

- Guideline No. 23 Product Audit of the Central Quality
Assurance Department
82
11.9.8 Flow Chart of the Product Audit Process
START
1
Scheduled audit according Unscheduled audit

to product audit plan for a specific reason
Performing
the audit
QA
Yes Critical nonconformity Yes

Any nonconformities or substantial deficiencies
etablished? found?
No No
Write and archive Information regarding
report results/deficiencies
QS
END
Yes Initiate corrective Implement corrective

Are corrective measures actions
actions required? QA PRD
No Write, distribute
and archive report
Write, distribute
QA
and archive report
QA
END END
83
Assess further aggregates
for the nonconformities/
1 deficiencies identified 2
QA
Further Yes Introduce and implement

nonconformities/
deficiencies found? immediate actions
No
Monitor
implementation
Information about in parallel
results/deficiencies QA
Initiate and implement

corrective actions Further
QA/PRD corrective actions Yes
required to eliminate
cause of the noncon-
formity long term?
Write, distribute
and archive report
QA No
Write, distribute
and archive report
QA
END
END
84
Establish corrective Monitor
Implement corrective
actions, verbally implementation
2 or in writing
actions
in parallel
PRD
QA/PRD QA
Write, distribute and

archive report
QA
END
85
12 Appendix: Reference to VDA 6.1
The following table provides a summary of product specific points from the
VDA 6.1 questions in connection with DIN EN ISO 9004-1, which might
need to be taken into account in a product audit.
VDA 6.1 Question Reference

Question Requirement/Explanation ISO 9004-1
No.
01.2 b) Quality objectives 4.3.1

Product-related objectives
01.6 periodical Management Reviews 5.5
02.5 Quality planning 5.3.3

Process and product validation
02.6. B) Quality plans 5.2.6

Plans for production products
03.3 Internal quality audits 6.2.2

Corrective actions
Evaluation/weighting of deviations regarding risk/product safety
03.4 Product audit 6.2.2

Audit plan ... after final inspection
04.2 Training program in quality techniques 18.11

Inspection and measurement techniques ... Product Audit
04.4 Introduction and instruction programs for new or altered 18.1.3

processes/prior to the introduction of self tests
04.5 Qualifications of employees necessary for legal and/or contractual 18.2

requirements (Material tester certificate, Welder certificate etc.)
05.3 Internal losses ... through inadequate product quality 6.2.2
05.4 External losses ... through inadequate product quality 6.2.2
06.2 Identification of products (documentation duties) 19.
06.3 Procedure for recognition of product risks 19 a, b
06.4 Emergency plan for nonconforming products 19 d, e
86
No.
07.1 Market analysis of a products quality requirements and expectations 7.1 a-c
07.3 Quotation ---

Establishing technical and commercial costs (cost blocks)
07.4 Quality requirements of the customer towards the product and 7.1 d
quality system
07.5 Product specification (Performance specifications) 7.2

Performance characteristics, installation instructions, applicable
standards, QA methods, packaging
08.1 Suitable product development plan for new products 8.1, 8.2,
(milestones/network plans) 8.10
08.6 Results of product development work documented in specifications 8.6, 8.8
9.1 Suitable process development plan for new/altered products 8.1, 8.2 8.10
9.3. Fulfilling product requirements through the process 8.2.4,

8.4.2a, b
10.1 Procedure for the identification, maintenance, review and release of 17.1
quality relevant documents
Identification: Clear classification of internal and customer specific
basic data
11.1 Quality requirements on the products and services in order 9.2

documents for suppliers
11.3 Sample verification of purchased products 9.3 b
11.6 Securing of supplied products and services/ verifying quality 9.7

evidence
11.7 Traceability of supplied products to suppliers 9.8
12.1 ... Quality measures/activities on customer-supplied products ---
13.1. Identification of products for internal processes 11.2
13.5 .. that only those products which comply with the quality 11.7
requirements reach the next process/process phase and dispatch
13.5 Data of products traceable, from dispatch back to entry 11.2
87
No.
15.1 Are all inspection activities and inspection process plans (product- 10.1.3
related presentation) represented with inspection instructions?
15.3. Are established quality records for delivered products maintained? 12.1
15.5. Are quality records maintained for end products? 12.3 a
21.2 Product observations and early warning systems regarding 7.3

production failures in the operating phase 16.5
16.6
21.3 Analysis of production failures 7.3.
Table 3: Product specific points in VDA 6.1 related to DIN EN

ISO 9004-1
88
13 Bibliography
13.1 Standards
13.1.1 DIN EN ISO 8402 (1995)
Quality Management and Quality Assurance - Definitions
13.1.2 DIN EN ISO 9000, Part 1 (08/94)
Quality Management and Quality Assurance; Guidelines for selection and

use
13.1.3 DIN EN ISO 9000, Part 2 (03/92)
Quality Management and Quality Assurance Standards; Generic

Guidelines for Selection and Use of ISO 9001, ISO 9002 and ISO 9003
13.1.4 DIN EN ISO 9001 (08/94)
Quality Systems; Model for Quality Assurance in Development, Production,

Installation and Servicing
13.1.5 DIN EN ISO 9002 (08/94)
Quality Systems; Model for Quality Assurance in Production and

Installation
13.1.6 DIN EN ISO 9004, Part 1 (08/94)
Quality Management - and Elements of a Quality System Guidelines
89
13.1.7 DIN ISO 10011 Part 1 (06/92)
Guidelines for Auditing Quality Systems; Auditing
13.1.8 DIN ISO 10011 Part 2 (06/92)
- Qualification Criteria for Auditors
13.1.9 DIN ISO 10011 Part 3 (06/92)
- Management of Audit Programs
13.2 Literature
13.2.1 VDA Publications for the Automotive Industry
Volume 1 Parts requiring Documentation at Car Manufacturers and

their Suppliers Documenting -, 1973
Volume 2 Quality Assurance of Supplies in the Automotive Industry-

Supplier Selection/Sampling Quality Performance in the
Series -, 2nd Edition 1995
Volume 3 Ensuring Reliability of Car Manufacturers and Suppliers

Procedures and Examples 2nd Edition
Volume 4 Quality Assurance prior to Serial Application

Revised in two parts
Volume 6 Part A: Quality Audit - Basics -, 1997
Volume 6 Part 1: Quality System Audit, 1996
Volume 6 Part 2: Quality System Audit Services
Volume 6 Part 3: Process Audit, 1997
Volume 6 Part 5: Product Audit, 1997
90
Volume 6 Part 6: Product Audit Services
Volume 7 Basics for Interchange of Quality Data Electronic

Transfer of Quality Data, 1994
Volume 8 Guidelines for Quality Assurance of Trailer, Superstructure

and Container Manufacturers, 1994
Volume 9 Quality Assurance Emissions and Consumption -, 1995
13.2.2 Masing, Walter (Publ.)

rd
Handbuch des Qualittsmanagement, 3 Edition, 1994
13.2.3 DGQ-Publication 11 - 04 (Status 1995)
Quality Management Definitions
Quality Assurance Manual/Guidelines for Preparation and Procedures
System Audit
Product and Procedure Audit
13.2.7 DGQ-Publication 14-18
Efficiency through Quality Management
91
13.3 References
- Verband der Automobilindustrie e. V. (VDA)

Westendstrae 61, 60325 Frankfurt
- Carl Hanser Verlag, Munich
- Springer-Verlag, Berlin, Heidelberg, New York
- Beuth-Verlag GmbH, Berlin
92
Other VDA-FORMS
FIRST SAMPLE TEST REPORT - new version

Cover Page, Order No. 2661
Test results, Order No 2662
Multipart form set, 5 copies (packed of 50 sets)
Outline form for process capability verification, Order No. 2663
Pad of 50 sheets - Minimum order 1 pad
FIRST SAMPLE TEST REPORT - present edition
First Sample Test Report - Report result, Order No. 5331
Multipart form set, 7 copies (packed of 50 sets)
First Sample Test Report - Test result, Order No. 5332
Pad of 100 sheets
SYSTEM - FMEA
- new version -
Order No. 7422, DIN A3 format, Pad of 50 sheets
FAILURE-POSSIBILITY- AND INFLUENCE-ANALYSIS (EMEA)
- old Version -
Order No. 769, DIN A3 format, Pad of 50 sheets
QUALITY SYSTEM AUDIT (Material products)
Questionnaire (onIy questions)
DIN A5, Pad of 10 sets 12 sheets
Evaluation documents
Final evaluation of the quality system
Summary of results
Total grading
Summary of evaluated questions
Individual measures
Corrective Aotions-Outline
DIN A4, Pad of 10 sets of 5 sheets
The two pads form a unit and are only offered as a set
Order No. 1749
Order:
DRUCKEREI HENRICH GMBH
Schwanheimer Strae 110, D-60528 Frankfurt
Telephone (069) 96777-158, Telefax (069) 96777-159
93
Quality Management in the Automotive Industry
Volume 1
Quality Evidence
Guidelines for Documenting and Archiving Quality Requirements
Volume 2
Quality Assurance of Supplies
- Supplier Selection/Sampling/Quality Performance in the Series -
Volume 3
Ensuring Reliability of Car Manufacturers and Suppliers
- Procedures and examples -
Volume 4 Part 1
Quality Assurance prior to Serial Application
-Partnerships, Processes, Methods
VoIume4 Part 2
QuaIity Assurance prior to Serial Application
- System FMEA -
Volume 4 Part 3
Quality Assurance prior to Serial AppIication
- Project Pianning -
Volume 6 Part 1
Quality System Audit, Basics DIN EN 150 9001 and DIN EN ISO 9004
Volume 6 Part 2
System Audit - Services
Volume 6 Part 3
Process Audit
Volume 6 Part 5
Product Audit
Volume 7
Basics for Interchange of Quality Data
- Electronic Transfer of Quality Data -
Volume 8
Guidelines for Quality Assurance of Trailer, Superstructure and Container
Manufacturers
Volume 9
Emissions and Consumption
94

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6

Verband der Automobilindustrie e.V. (VDA)

Verband der Automobilindustrie e.V. (VDA)

If during the use of VDA guidelines, errors or the possibility of misinterpre-

With respect to technical and economic progress, quality assurance deter-

The production process consisting of many individual processes has to take

VDA 6 VDA 6 Quality System Audit

VDA 6 VDA 6 Product Audit

The product audit shall demonstrate the quality niveau of internally/exter-

A practical representation of the product audit was chosen, to make the

Aktiengesellschaft Khnle, Kopp & Kausch, Kirchheimbolanden

and hope, that this publication finds successful application.

Frankfurt/Main, April 1998

VERBAND DER AUTOMOBILINDUSTRIE E. V. (VDA)

2 Definitions and Purpose of a Product Audit 11

3 Product Audit at Car Manufacturers and Suppliers 14

4 Preparation and Planning of Product Audits 17

5 Product Audit Questionnaire 20

6 Performing a Product Audit 21

7 Analysis of the Data and Investigation of Causes of

8 Evaluation of the Product Audit Results 24

9 Product Audit Report 25

12 Appendix: Reference to VDA 6.1 86

A product audit assesses the effectiveness of quality assurance through the

The focus of the evaluation of deviations from the specification lies,

Product audits can be carried out in all business processes like,

product development product manufacturing - product marketing.

This publication primarily deals with product audits in product manufac-

Product audits are an integral part of a quality system according to

- checking the compliance of development results with the in-

An important precondition for the performance of product audits is the

2.1.1 Quality Audit (according. to ISO 8402 : 1994)

Systematic and independent examination, in order to ascertain, if the

Note: A quality audit is typically carried out on a quality system or an element

2.1.2 Product (according to ISO 8402 : 1994)

Result of activities and processes.

A p r o d u c t a u d i t is the planning, performance, evaluation

of - quantitative and qualitative characteristics

The performance of the examinations follows a defined audit plan.

It is the task of a product audit, to check normally delivery-ready products

As a priority, system faults, nonconformity focal points and long term

The purpose of a product audit, for a company, is to recognize deviations

Knowledge of all customer expectations of a product is necessary during a

The supplier or manufacturer gains a comprehensive picture of the quality

3.1 Distinguishing a Product Audit from other Audit Types

The process of a product audit is schematically shown in the following.

Product Audit Process

Audit report Inform responsible departents

Long term Inclusion of results in

*) Unscheduled audits are specifically initiated.

If specific assesments are included in the long term evaluation,

4.1 Preconditions and Responsibilities

a) Inclusion of a statement regarding the carrying out of product

4.2 Audit Program

and the inspection and testing methods and equipment to be applied.

4.3 Reference Documentation

- Drawings with amendment status

When selecting inspection, measuring and test methods and equipment,

- measuring uncertainty of the inspection, measuring and test

4.5 Auditor Qualification

The success of a product audit depends to a large extent, on the technical

- knowledge of the purpose of the product audit

In order to ensure the successful performance of a product audit, thorough