VDA 6.3 Process Audit: A Complete Practical Guide

VDA 6.3 Process Audit : A Complete Practical Guide for Automotive Professionals

VDA 6.3 Process Audit, The global automotive industry is undergoing rapid transformation. Vehicles are no longer just mechanical machines; they are becoming complex cyber-physical systems integrated with electronics, software, safety systems, connectivity, and automation. As complexity increases, the risks associated with poor processes also increase—warranty failures, recalls, customer dissatisfaction, legal penalties, and even life-threatening hazards.

To tackle these risks, automotive organizations must not only implement quality management systems but also ensure that processes are robust, repeatable, and continually improving. This is where VDA 6.3 Process Audit becomes essential.

VDA 6.3 is not just another audit checklist. It is a deep-dive process evaluation methodology developed by the German Association of the Automotive Industry (VDA) to assess and improve product development and manufacturing processes across the automotive supply chain.

Unlike ISO 9001 or IATF 16949 — which focus mainly on the quality management system — VDA 6.3 focuses directly on how processes are executed on the shop floor, supplier facilities, engineering teams, logistics, and customer service. It highlights risks early and prevents issues before they reach customers.

In this guide, you will learn:

• what VDA 6.3 is
• why companies use it
• detailed explanation of P1–P7 elements
• examples of audit questions
• scoring method and result interpretation
• benefits for organizations and professionals
• common mistakes and best practices
• difference between VDA 6.3 and IATF 16949
• how to become VDA 6.3 certified

This article is written in simple language, yet deeply informative, so it is useful for students, engineers, auditors, and industry professionals.

What is VDA 6.3 Process Audit?

VDA 6.3 is an internationally recognized process audit standard created by the German automotive industry (VDA). It is used to evaluate whether processes in product development, supplier management, and manufacturing are capable of consistently delivering quality products.

It is applicable to:

• internal process audits
• supplier audits
• new project audits
• serial production audits
• risk assessments during sourcing
• customer-specific requirements audits

VDA 6.3 helps organizations to:

• detect weak processes early
• identify risks before SOP
• avoid defects and customer complaints
• improve process capability and stability
• build confidence with OEMs and Tier-1s

Today, many automotive OEMs such as Volkswagen, BMW, Mercedes-Benz, Audi, Porsche, Stellantis and global Tier-1 manufacturers mandate VDA 6.3 compliance for their supply chains.

Why VDA 6.3 Process Audit is Important for Automotive Manufacturers

1. Globally Recognized Quality Standard

VDA 6.3 is accepted worldwide and demonstrates that an organization follows structured, risk-based process control. It adds credibility during:

• customer audits
• new business acquisition
• RFQ evaluations
• supplier nominations

2. Covers Entire Product Lifecycle

VDA 6.3 spans all stages including:

• idea & concept development
• design and manufacturing planning
• prototype builds
• serial production
• customer support

This end-to-end approach ensures no gaps in product realization.

3. Strengthens Supplier Management

Modern manufacturing is supply-chain driven. If supplier processes are weak, your product quality becomes weak. VDA 6.3 enables organizations to:

• evaluate suppliers regularly
• assess risk before sourcing
• monitor supplier performance
• support weak suppliers through development

4. Supports IATF 16949 and ISO 9001

While VDA 6.3 is not a replacement for IATF 16949, both complement each other. IATF builds system discipline, whereas VDA 6.3 ensures process discipline.

5. Reduces Cost of Poor Quality (COPQ)

Poor processes lead to:

• rework
• scrap
• customer complaints
• field failures
• recalls
• brand damage

VDA 6.3 focuses on prevention, which is always cheaper than correction.

6. Improves Customer Satisfaction and Trust

Consistent, defect-free products automatically result in:

• customer trust
• repeat orders
• long-term business relationships

Structure of VDA 6.3 Process Audit

VDA 6.3 is structured into seven process elements (P1 to P7):

1. P1 — Project Management
2. P2 — Planning Product and Process Development
3. P3 — Realization of Product and Process Development
4. P4 — Supplier Management
5. P5 — Process Analysis: Production
6. P6 — Customer Service
7. P7 — Overall Evaluation and Result

Each element contains scoring questions with weighted importance.

P1: Project Management – VDA 6.3 Process Audit

P1 evaluates how well the project is planned and controlled from quotation stage to SOP.

It focuses on:

• resource planning
• milestone tracking
• risk management
• communication and escalation
• cross-functional team definition
• change control
• customer requirement review

Strong project management prevents:

• launch delays
• cost overruns
• chaos during SOP

P2: Planning of Product and Process Development

P2 ensures that product and process design planning is structured and risk-based.

Audit checks include:

• feasibility study
• APQP planning
• DFMEA & PFMEA planning
• legal and customer requirement review
• prototype planning
• change management process

Good P2 planning reduces:

• re-designs
• engineering change cost
• project delays

P3: Realization of Product and Process Development

P3 assesses how design and process plans are implemented in reality.

This includes:

• prototype builds
• validation plans
• test result analysis
• maturity tracking
• lessons learned usage
• controlled change implementation

This phase decides whether you are ready for serial production.

P4: Supplier Management

P4 ensures that suppliers:

• are qualified
• are capable
• are monitored
• receive support
• meet customer expectations

Supplier issues are one of the biggest risks in automotive manufacturing, and VDA 6.3 helps mitigate them.

P5: Process Analysis – Production

P5 is the heart of VDA 6.3. It evaluates shop-floor production performance.

It observes:

• process capability (Cp/Cpk)
• control plans
• work instructions
• poka-yoke systems
• preventive maintenance
• operator skills
• SPC monitoring
• reaction plans

Objective: stable, repeatable, capable production.

P6: Customer Service

P6 evaluates post-delivery activities, such as:

• warranty handling
• complaint management
• spare parts availability
• customer communication
• field failure analysis

Good P6 performance builds long-term loyalty.

P7: Overall Result Evaluation

P7 summarizes all results and assigns ratings:

• A – Capable (90–100%)
• B – Conditionally Capable (80–89%)
• C – Not Capable (<80%)

Mandatory questions not fulfilled result in automatic C-rating.

VDA 6.3 vs IATF 16949

They are complementary—not competing.

Who Should Get VDA 6.3 Certification?

• Quality Engineers
• Supplier Quality Engineers
• Process Engineers
• Auditors
• Production Managers
• Supplier Development Teams
• Lean & Six Sigma professionals

Benefits of VDA 6.3 Certification

You will:

• gain deep process audit expertise
• improve employability
• qualify for better job roles
• perform professional supplier audits
• support IATF 16949 implementation
• lead improvement initiatives

This certification is highly valued in:

• OEMs
• Tier-1 suppliers
• Consulting companies

Common Mistakes Seen During VDA 6.3 Audits

• poor documentation
• lack of risk analysis
• missing FMEA linkages
• untrained operators
• outdated work instructions
• weak change management
• data recorded but not analyzed
• temporary fixes instead of root cause analysis

How to Score Well in VDA 6.3 Audits

To achieve A rating:

• demonstrate risk-based thinking
• provide objective evidence
• link APQP → FMEA → Control Plan → Production → SPC
• show trend analysis
• ensure training records exist
• apply poka-yoke rather than inspection
• ensure top management involvement

VDA 6.3 is far more than an audit checklist. It is a complete methodology to build world-class manufacturing processes. Organizations that adopt VDA 6.3 develop:

• strong process discipline
• predictable outputs
• reduced wastes
• improved customer trust
• competitive advantage

As automotive technology advances — EVs, ADAS, autonomous systems — process robustness becomes mission-critical. VDA 6.3 helps ensure safety, reliability, and performance.

If you are in the automotive sector, mastering VDA 6.3 will significantly strengthen your career and your organization’s capability.

✅ VDA 6.3 Process Audit – FAQ

1. What is VDA 6.3?

VDA 6.3 is a process audit standard developed by the German Automotive Industry Association used to evaluate and improve product development and manufacturing processes in the automotive supply chain.

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2. Is VDA 6.3 mandatory?

It is mandatory for suppliers to German OEMs such as Volkswagen, BMW, Audi, Mercedes-Benz, Porsche, etc.
For others, it is strongly recommended as best practice.

3. What is the purpose of a VDA 6.3 audit?

The main objectives are to:

• identify process risks
• prevent defects before they occur
• improve process capability
• enhance customer satisfaction

4. Who conducts VDA 6.3 audits?

Audits are conducted by:

• certified VDA 6.3 auditors
• trained internal auditors
• OEM or Tier-1 supplier auditors

5. What are the 7 elements of VDA 6.3?

The elements include:

• P1 – Project management
• P2 – Planning product/process development
• P3 – Realization of development
• P4 – Supplier management
• P5 – Process analysis—production
• P6 – Customer service
• P7 – Overall evaluation

6. What is the scoring system in VDA 6.3?

Scores classify processes as:

• A (90–100%) – Capable
• B (80–89%) – Conditionally capable
• C (<80%) – Not capable

7. What happens if a supplier scores “C”?

A C rating means non-compliance.
Corrective actions and re-audit are required before approval.

8. What is the difference between VDA 6.3 and IATF 16949?

• IATF 16949 = quality management system standard

• VDA 6.3 = process audit methodology

They complement each other but are not replacements.

9. What industries use VDA 6.3?

Primarily:

• Automotive OEMs
• Tier-1 & Tier-2 suppliers

Also applied in:

• EV battery manufacturing
• electronics
• plastic molding
• sheet metal manufacturing

10. What training is required to become a VDA 6.3 auditor?

You typically need:

• quality or engineering background
• audit experience
• completion of VDA 6.3 training course
• passing written and oral exam

11. What documents are checked in VDA 6.3 audit?

Common requirements include:

• control plans
• FMEA
• process flow diagrams
• work instructions
• PPAP documents
• APQP records
• KPI monitoring records

12. Does VDA 6.3 cover product audits?

No — product audit is part of VDA 6.5.
VDA 6.3 focuses on process audits.

13. How long does a VDA 6.3 audit take?

Depends on:

• plant size
• number of processes
• scope

Typical automotive plants require 2–5 days.

14. Can VDA 6.3 be applied to service industries?

Yes.
It is mainly automotive-focused but adaptable to:

• logistics
• engineering services
• component trading

15. What happens after the audit?

The organization receives:

• detailed audit report
• element-wise scoring
• risk classification
• corrective action plan

16. What are common reasons for failing VDA 6.3?

Frequent causes:

• weak FMEA

• missing risk management

• poor supplier control

• lack of evidence

• untrained operators

• uncontrolled processes

17. How often should VDA 6.3 audits be conducted?

Typical frequency:

• annually for high-risk suppliers

• every 2–3 years for stable suppliers

Internal audits may be performed more frequently.

18. Is VDA 6.3 applicable to new product development?

Yes — it is especially powerful for:

• NPD projects
• SOP readiness
• APQP stages

19. Can small companies implement VDA 6.3?

Yes.
It improves:

• discipline
• documentation
• customer trust

Even SMEs gain a competitive edge.

20. What is the benefit of VDA 6.3 to individuals?

Professionals gain:

• higher salary prospects
• strong industry recognition
• career opportunities in OEM/Tier-1 firms