VDA6 Product Audit Part 5.doc

VDA Quality Management6 in the Automotive Industry Product Audit Part 5 1st Edition 1998 3 Product Audit1st Edition 1998Verband der Automobilindustrie e.V. (VDA)ISSN 0943-9412Copyright 1998 byVerband der Automobilindustrie e.V. (VDA)(Association of the German Automotive Industry)Quality Management Center (QMC)D-60325 Frankfurt am Main, Lindenstra?e 5Overall production:Druckerei Henrich GmbHD-60528 Frankfurt am Main, Schwanheimer Stra?e 110Printed on chlorine-free bleached paper.2Liability exclusionThe 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 ineach specific case.The VDA volumes take into account state of the art technology, current atthe time of issue. By using the VDA guideline, nobody is relieved of theresponsibility for their own actions. Each person acts, in this respect, at theirown risk. Liability by VDA, and those persons involved in issuing VDAguidelines, 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 standardsThe extracts from standards identified with their DIN number and issue dateare reproduced with the permission of the DIN Deutsches Institut frNormung e.V. (German Institute for Standardization). The version with thelatest issue date is definitive for the use of the standard, which can beattained from the publishers Beuth Verlag GmbH, 10772 Berlin.CopyrightThe publication, including all its parts, is protected by copyright. Any useoutside of the narrow boundaries of copyright law, without the writtenpermission of the VDA, is unauthorized and illegal. This applies in particularto copying, translation, microfilming and the saving and processing inelectronic systems.34ForewordWith 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 takeinto account rational and economic aspects in order to achieve an optimumin quality, time and costs. To ensure this, the VDA has issued the followingguidelines for the quality standard of the automotive industry:QUALITY STANDARDOF THE GERMAN AUTOMOTIVE INDUSTRY (VDA 6)VDA 6VDA 6Part 1Quality System AuditVDA 6Quality System AuditPart 2ServicesQualityVDA 6AuditsPart 3Process AuditVDA 6VDA 6Product AuditBasicsPartAudit 5Product Part 6ServicesThe 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 conclusionsregarding the production process and if necessary, the quality system arepossible.The information gained from product audits promote the continuos processof quality improvement, to the benefit of customers and suppliers.A practical representation of the product audit was chosen, to make thecontent of the publication easily understandable.Guidelines are provided for the planner of product audits and productauditors.The subject ?Product Audit? is then rounded off with actual examples frompractice.5We thank the following involved companies and their employees for theirinput in the preparation of this publication:Aktiengesellschaft Khnle, Kopp & Kausch, KirchheimbolandenContinental AG, HannoverFichtel & Sachs AG, SchweinfurtFord-Werke AG, CologneGLYCO-METALL-WERKE Glyco B.V & Co. KG, WiesbadenDaimler-Benz AG, Hamburg WorksTRW Deutschland GmbH, Motor Components, BarsinghausenTHYSSEN KRUPP STAHL AG, DuisburgVolkswagen AG, WolfsburgZDH-ZERT e.V., Bonn.and hope, that this publication finds successful application.Frankfurt/Main, April 1998VERBAND DER AUTOMOBILINDUSTRIE E. V. (VDA)6Content PageForeword51Introduction112Definitions and Purpose of a Product Audit132.1Definitions132.1.1Quality Audit (according. to ISO 8402 : 1994)132.1.2Product (according to ISO 8402 : 1994)132.1.3Product Audit142.2Purpose153Product Audit at Car Manufacturers and Suppliers163.1Distinguishing a Product Audit from other Audit Types163.2Process of a Product Audit184Preparation and Planning of Product Audits194.1Preconditions and Responsibilities194.3Reference Documentation204.4Inspection, Measuring and Test Methods and Equipment214.5Auditor Qualification215Product Audit Questionnaire225.1General225.2Questions to the Physical Examination of a Product225.2.1Review of all Documents225.2.2Random Sampling226Performing a Product Audit236.1Responsibility236.2Process236.3Reporting (Documenting)247Analysis of the Data and Investigation of Causes ofNonconformities258 Evaluation of the Product Audit Results269 Product Audit Report27710Corrective Actions Resulting from the Production Audit2810.1General2810.1.1Corrective Actions for Major Nonconformities2810.1.2Corrective Actions for Minor Nonconformities2810.2Monitoring of Corrective Actions2811Case Examples2811.1Case Example Selector Shaft - Mller + Co.2911.2Case Example Input Material (Sheet metal)- Thyssen Stahl AG3511.3Case Example Laser and Mash Seam Welded Tailored Blanks- Thyssen Stahl AG11.3.1Selecting Samples for Inspection4011.3.2Scope of Inspection4011.3.3Process and Sequence of Operations4011.3.4Product Audit Report4111.3.5Procedure for Handling Nonconformities4111.3.6Dispatch Audit4211.3.7Responsibility4211.4Case Example Bearing Bush - AG Khnle, Kopp & Kausch4511.4.1Explanation Systematic Quality Evaluation Productionand Purchasing (SQPP)4511.4.2Code Number System for SQPP4711.4.3Procedure using Bearing Bush as an Example4911.5Case Example Valves - TRW Deutschland GmbH,Motor Components5611.6Case Example Tires - Continental AG6111.6.1Scope and Frequency of Inspection6111.6.2Specifications, Inspection, Measuring and Test Methods6111.6.3Process6Auditor6Visual Inspection6Machine Tests6211.6.4Documentation6211.6.5Evaluation6211.6.6Forms6Visual Inspection6Concentricity62811.7Case Example Complete Vehicle - FORD AG6511.7.1Check of Conformity6511.7.2Complete Vehicle6511.8Case Example Complete Vehicle - Volkswagen AG7411.9Example of a Product Audit Procedure - Mercedes Benz AG,Hamburg Works8111.9.1Purpose8111.9.2Scope8111.9.3Terms and Definitions8Product Audit8111.9.4Responsibilities8Product Audit8211.9.5Description83Performing the Product Audit83Product Audit Plan8411.9.6Additional Notes8411.9.7Applicable Documents8411.9.8Flow Chart of the Product Audit Process8512Appendix: Reference to VDA 6.18813Bibliography9113.1Standards9113.1.1DIN EN ISO 8402 (1995)9113.1.2DIN EN ISO 9000, Part 1 (08/94)9113.1.3DIN EN ISO 9000, Part 2 (03/92)9113.1.4DIN EN ISO 9001 (08/94)9113.1.5DIN EN ISO 9002 (08/94)9113.1.6DIN EN ISO 9004, Part 1 (08/94)9113.1.7DIN ISO 10011 Part 1 (06/92)9213.1.8DIN ISO 10011 Part 2 (06/92)9213.1.9DIN ISO 10011 Part 3 (06/92)9213.2Literature9213.2.1VDA Publications for the Automotive Industry9213.2.2Masing, Walter (Publ.)9313.2.3DGQ-Publication 11 - 04 (Status 1995)9313.2.4DGQ-Publication 12 - 62 (Status 1991)9313.2.5DGQ-Publication 12 - 63 (Status 1993)9313.2.6DGQ-Publication 13 - 41 (Status 1995)9313.2.7DGQ-Publication 14-189313.3References949101IntroductionA product audit assesses the effectiveness of quality assurance through theexamination of a small number of products and/or parts and confirms theirquality capability based on the quality of the product. Thereby, it is checked,if the product complies with the given specifications, or respectively, withspecial 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 afterlong term use, are determined. It does not serve as a substitute forinspections during the production process.Product audits are carried out regularly. Irrespective of this, they can also beadditionally carried out for a specific reason. They must be planned andprepared by qualified personnel, before they are carried out. Every audit, itsresults, improvement measures, as well as responsibilities are to be docu-mented.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. Incertain cases, it can lead to the conclusion that system failures exist, whichthen initiates further audits such as process or system audits being carriedout.Product audits are an integral part of a quality system according to VDA 6.1.The company management must identify with the duties and objectives ofthe product audit.11The following decision criteria can be useful for the application of productaudits in a company:-checking the compliance of development results with the inputs(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 theavailability of an appropriately organized structure, that allows audits to besystematically and independently carried out.The audit plan defines at which stage in the production process, productaudits are carried out. In the audit plan, questions about the efficiency, com-plexity of the products and the number of production pieces are included.122Definitions and Purpose of a Product Audit2.1Definitions2.1.1Quality Audit (according. to ISO 8402 : 1994)?Systematic and independent examination, in order to ascertain, if the quali-ty activities and related results, comply with given instructions, and if theseinstructions are efficiently put into action and are suitable to achieve theirobjectives.?Note:A quality audit is typically carried out on a quality system or an elementthereof, on processes or products (including services), but is not restrictedto these. Such quality audits are often called ?system audits?, ?processaudits?, product audits?, or ?service audits?.One purpose of a quality audit is to assess the need for an improvementor corrective action. A quality audit should not be mistaken with qualitymonitoring activities or reviews, which are carried out for process controlor product receiving purposes.Quality audits can be carried out for internal or external purposes.2.1.2Product (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) orintangible (e.g. knowledge or concepts) or a combination thereof.A product can be intended (e.g. product offered to customers) orunintended (e.g. pollutants or undesirable effects).132.1.3Product AuditA p r o d u c t a u d i t is the planning, performance, evaluation anddocumentation of e x a m i n a t i o n sof -quantitative and qualitative characteristicson-material productsafter-completion of a production stageand before-its forwarding to the next customer(internal/external)on the basis -of reference valuesthrough -an independent auditor.Note 1:Material products are the result of activities and processes and are, forexample, raw materials, intermediate products of all types including com-ponents, assemblies, and subassemblies, as well as end products, whichare to be delivered to the customer. During a product audit, the propertiesin new condition and not after long term use, are determined.Note 2:Both internal or external customers can be meant. One can also under-stand ?customer“ to mean a further process or a subsequent productionmachine.Note 3:The product audit is generally carried out by the product manufacturer(supplier). It is useful for the performance of a product audit touse DIN ISO 10011 Part 1. The auditor must know the product and itsproduction process, or have access to information carriers. Furthermore,depending on the objectives, he has information that describe customerreactions 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 thefollowing points are to be established in the product audit plan: type andextent of samples or parts, type and number of the characteristics to bechecked, inspection, measuring and test method and equipment, and eva-luation of the examination results in comparison to the internal and/orexternal standards or specifications and drawings.Note 5:The result of the evaluation of a product audit is to be regarded as areview of all quality control measures.When deviations from the specifications are found, corrective actions areto be taken. Immediate actions like e.g. stopping or re-sorting the entireproduction and, if necessary, in development, are required, whendeviations from specified values and/or limit patterns of importantcharacteristics ? especially safety characteristics, are found.14Note 6:Product audits can be carried out on prototypes and after all productionphases until delivery. Audits at different production phases and, ifapplicable, the delivery product audit performed from a customers point ofview, are methodically attuned to one another.2.2PurposeIt is the task of a product audit, to check normally delivery-ready productsaccording 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 verycomprehensively and from the customers point of view.As a priority, system faults, nonconformity focal points and long term qualitytrends are to be ascertained. For the elimination measures to beimplemented, recognized nonconformities are to be separated into syste-matic and coincidental nonconformities. In serious cases, immediateactions in the production process are implemented. The respective checkrepresents the momentary situation. The audit in its entirety over a timeperiod, shall illustrate the quality potential of the production. The scope ofinspection is determined by the complexity of the product and the number ofproduction pieces.The purpose of a product audit, for a company, is to recognize deviationsand 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 aproduct audit. These should be externally evaluated and methodicallyintegrated into the product audit. In this way, for example, noises could beevaluated to see if, and to what extent, they are regarded as disturbing bythe customer.The supplier or manufacturer gains a comprehensive picture of the qualityof his products and the acceptance of these products by the customer.153Product Audit at Car Manufacturers and Suppliers3.1Distinguishing a Product Audit from other Audit TypesThe product audit shows only partial similarities to other audit types or withother product assessments. An exemplary distinction, which does not claimto be exhaustive, is shown in Table 1.16 Inspection verification Product Audit System Audit Process Audit 100% inspection, Final inspection, S P C measuring and testing measurement and testing First sample Works in serial production inspection certificate Performance acc. to plan, generally several acc. to plan, generally once a acc. to plan and as necessary continuously continuously acc. to cust. acc. to cust. continuously frequency times a year year requirements requirements Checked selected acc. to customer elements of the quality system selected, as necessary for qualitative characteristics, selected, product related, acc. acc. to cust. selected, and acc. to selected, as required for characteristics requirements /expectations and process evaluation incompetent characteristics to customer expectations requirements cust. requirements process control important process and product characteristics Capability short term capability of the (degree of compliance with the short term capabilities of the (qualitative characteristics e.g. short and long term capabilities acc. to customer requirements automatic identification of the parameters product characteristics on the system objectives) process parameters cpk < 1,33) of the product characteristics short and long term basis of the selected sample. capabilities Feedback to production Applied selected, specific for the product document review compared to selected, specific for the selected, specific for the product selected standard method, selected with the agreement of the customer selected, specific for the verification the objective, the application in process specific for the product process or product methods practice Qualification of knowledge of the product and DIN ISO 10011, Part 2 + EOQ knowledge of the process knowledge of the knowledge of the knowledge of the characteristics, customer knowledge and experience the auditors / production process, also from Certificate + characteristics characteristics and customer requirements and relevant standards of control card technology inspectors the customers point of view VDA 6.1 Certificate expectations Necessary drawings, specifications, work quality manual, procedures and process pla