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    635 views28 pages

    Vda 6.5

    Uploaded by

    Hang Nguyen

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    © All Rights Reserved
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    VOR. Verbomd cov ISSN 0943-9412 Printed 09/08 Reprint 2014/09 Copyright 2008 by Verband der Qualitts Na 10117 Bertin, Germany Automobitindustrie 6.V. agement Center (QMG\ Behrenstrage 35 Overall production Henrich Druck + Med GmbH 60528 Frankfurt am Mem Germany: Su a Main, Schwanheimer Strage 440 Printed on chlorine-free bleached Paper 6 Ha F ons Prutrolal: Induaine~. £ nga ree | Non-committal VDA recommendation regarding standards | The Verband der Automobilindustrie (Automotive Industry Association - | VDA) proposes that its members apply the following recommendations | Jegerding standards when establishing and maintaining QM systems, | Exelusion of responsibility : This VDA document is a recommendation which is free for anyone to use. ‘Anyone using it must ensure that it is applied correctly in each individual case. This VDA document takes account of the latest state time it is issued. The application of the VDA reco any way relieve the user of his own responsi document. To this extent, the user applies the document at his own risk. The VD: those involved ff drawing up the VDA recommendations decline ity in any circumstances. Anyone using these VDA recommendations detecting incorrect cr the possibilty of incorrect arrangements without delay, so that any deficiencies can be References to standards ‘The individual standards referred to by their DIN number and their date of issue are quoted with the permission of the DIN (German Standards Institute). It is essential to use the latest issue of the standards, which are available from Beuth Veriag GmbH, 10772 Berlin, Germany. Copyright This document is protected by copyright. Its use outside the strict limits of the copyright laws Is prohibited wit of the VDA and is punishable by law. This ar regard to copying, translating, micro-filming and storage and processing in electronic systems. Translations This document will also appear in other languages. Please contact the VDA QMC for the latest position. UUoHJenyeno stoug pue suoneIep BuL\ysse;o UO SeION Buruodey supne yonpcud yno Bukues squotunoop eoussejey, sn ic) spied BuILTIeS sued Supjeed sue Buniodsuey, syed Guyfinuap] ‘i syed Bure) Uuoyeounuep! sou) g sped Bupyer.o} squewarndexy 223s ajdies wopues pue juouxcinbs ; spouewi Bupioeus Suopeoyjoods pur payoayo 3q 1 soqsuayDereyS ued wony weiBoid ypne euy Bunenier > pue But0y 014 uresBoid jpne 24j Suquowieiduu ‘seaunos 9) wiesBoud ypniy UesBoud sipne ue Jo 1U3>3 uresBaud ypne 24) Guip 2621 suo} syoeuo (uonanpoud Jo Ausi0} 409) sonoedsu ‘eye indy} wesBoid ony upne yonpoud eno Buykues uopeaudde jo eo1e pue eanoolag aonyaid soluedwios Burmoy SUOWOD HLA Joy soaxoydt (AN) 2 e1nsnpugowouny Jap puogiog 2002 ¥snBny esuniogo ‘euuncop au Buy USA ene eaitlt Pu BuREH0Ue6 wy eouRysose wu Ue quaweBeinco ae 04M HE 01 08 ose sHueut ng SY UoBemsyioy SY sonuieg ‘sBneziyeyann eddrig Nyy - Ovorseqamy, Sv suses az HOW Nas esweig wou Haw yosog weqoy winton oy dn Buywerp ul porjonu) exem, HO} PULL ueLUND0p 1M 30 uok wo luo 7oin pue suonesnietio Sugeno __ Seas Corrective actions Immediate actions Knowledge transfer Qualifications Audit planner Auditors, of the audit planner and auditors Reference documents Technical terms & abbreviations Page4 Preface 30 since the appearance, 31 the first edition in April 1998 condittons for manufacturers and suj to the automotive industry have changed markedly. Automotive-specific requirements laid down in standards with international validity, such as ISO/TS 16949, now form the basis for quality ‘management in the automotive industry. From the experience gained with the requirements it has been seen that the difference between the terms “product audit” and “requalification.check" is open {6 interpretation. This present volume sets Out a recommendation in differentiating between the terms. roduction of the ISO/TS ‘The new edition is based on the requirements of ISO 19011 : "Guidelines for Quality and/or environment management systems auditing Unlike the first edition, this current volume. does not contain concrete examples. Instead, a. code..ofpractice has been created for the management of product audit programs, which will enable companies to Gevelop their own systems to suit their patticular products. Meanwhile, the quality of products is ensured by the consistent implementation of preventive quality planning methods. The task of a product audit is therefore not merely to ensure quality but also to provide proof of compliance. More stringent customer demands, safety requirements, legal regulations and the ever-increasing use of electronic components and software lead to greater product complexity. The expectations of end-users can no longer be cor specifications. Vehicle manufacturers and suppliors industry are expected to Identify these product charac responsibility and to reproduce them in their products. be bore in mind when carrying out products audits. ied merely in \e automotive ‘As part of the process chain the product audit should illustrate the quality level of the products manufactured in-house and outside. This 2nd edition of VDA Volume 6.5 : "Product Audit" replaces the 1° edition. A production process must take inte secoant eae? OF @ Series of many individual processes. ig Objective and area of application achieve the opti {ange of rational anc economic aspects in order ty ~ d ist the VDA hae ieee” terms of quali, price and delivery. To ennai) led a co ’ Q automotive Industry, as follows, © St fF quality standards in QUALITY STANDARDS _____OF-THE GERMAN AUTOMOTIVE INDUSTRY (VDA 6) fg confor ‘the product audit serves as a management tool for the independent é evaluation of products from the customers’ viewpoint and to provide fabilty claims arising from deficiencies in products and potential for continuous improvement. teristics of the product are checked product dimensions; materials; jentification) and known customer n (e.g., packed; the product as new; Ina product audit the specified charz ith the parts OM aye / ] Qttavstem epectations in a specified con voas one | audi ior a © | pretutton | | YOAS | stam Sua er me [pear] (AS zee, | yee] aetna oe) services | equipment 7 ; i T . | Product autis can be carried out at any stage in the manufacturing | cua aust | [process : | | | voas Process a Frocess] on somifnished or finished items from an individual process imei nt vors| suc + Production products services PAS | eutstor | on components (e.g, 2 bolt, hose, crankcase, etc) Fundamentals Broun | "Gh assemblies such 2s a control uni, injection pump, oa oe auxiliary heater, motor, transmission, bodywork Pore. Prodéct audit = on the complete vehicle rE | (rateal an non mater) i ‘A product audit is not intended as : (VDA 6) Code of practice e for quality standards in the automotive industry = @ repetition of in-production inspection operations: = ameans of direct process control general proof of the effectiveness of a quality management system An important requirement for carrying out systematic and independent product audits is the presence of an appropriate organisational structure. This code of practice describes the area of application of a product at and gives suggestions for the management of an audit program. Ess audit activities are explained, together with requirements covering auditors. A product audit highlights mein areas for criticism and illustrates quality trends. It is sometimes possible to trace back to weaknesses in the system. ‘or process, paving the way for further audits such as process and system audits. ‘The product audit has only a limited amount in common with other product checks and inspection. The degree to which a product audit differs from other checks is set out in Table 1, as follows : Table 1: Differences between product audit and other he asics cote ln does ot ies, erewcns g snc ub eshingcbosie see Product audit Improsess checks Requafication 5 Carrying out a product audit ‘ Covered bythe requirements of Sos | (eg. monitoring " vidual stages of a product audit. ‘eet and Brovoss params, i chematic shows the indi : a vont '$°C, tonale stengh see eee Sgach case is indisated in the following Sections of teres, te) The |document. | The purpose ofa productauatie | Paposs | + todenty the potential for Process cont —_— | «ert ane [rasa] umes | (internal & external) regarding the ~ fished progr eee + fake aocoun of tans cevantio | | the customer (6g, ooadar feedback | ] from the fleid) | + 10 prove reat recvremenis | | * t9prove th inerpay of proc! charaserates (uredon shee + 1 demonstate characteris oot checked nthe producion sonra plan’! | + fo demonsrate produc charactrsts vin may hunoe castomer ‘stecion + 10 comonstate product cheractestos Checked vs eguvalents ningrocaes checks? Carry out + to demonstrate packing and labeting Para.6| oduct audit Frac y Frequency : L = a rece conte pan | — steed Para.7| Reporting broducton ' I Docureraton Traut esuts | Gocanenaion? | Goon ae canes Gieivapaman teats evaluating results evaluating results Para. 8 foaae | Aut rere Tote production | To tha producion Patol the management review contol len conta pan | equalisation deamon Contes Contes Conteris Segitateetes gaye | Pete rae Barf cntact Fig. 1: Overview of the sequence of a product aul covers customer requirements: i = enemas eee | ‘checks. ey padit oaracaresen eter bocce sno cl ar ean * _Ferexmnpisolneisfow sa chracterate raced a pesca: or wast ogi 40 4 Audit program Defining the objectives and developing the audit program -Specty the prods obo austes Define te ‘associated audit objectives: + Define the responsibilities 7 Pan te resources ~Approve the aucit program Sete ec feims of planning, organisation and execution, so that the planned cous $n Pe cared out efficiently and effectively within the specified ime pers This ‘also includes the provision of personnel and checkinglinspection resources, for the audit program lies with the person responsible for jement, Responsi quality mar * —Imptement tne aualt program = Communicate the audit program ran the objeceiven = Provide the necessary resources: “i with he Ensure the audits are carried out eee ~ Record the audit activities Evalusto end = Ensure that audit folow-on actos are taken le—! the audit program CCheck thet the cbjoctves ofthe product ‘ucts and audit program are achievee Moni Fig.2: Process sequence for managing an audit program 44 Input criteria staan ‘the following general input criteria are to be considered and may be ‘expanded to include others: ey evs Saaye E le — Customers’ requirements (specified) ls = Customers’ expectations recognized by the company, which have an important part to play in customer satisfaction (not specified) ls — tntemal specifications — Complaints/rejects from intemal and external customers res; guarantee data, ta) rom risk assessments of customer satisfaction surv Conelusions and actions from previous product audits Legal regulations and cheoks required by law Features of strategic importance; possible risks for the edb: r ps fea ar a moje RAD and a ep on te E autor Oh ati reavae In addition there are in-house conditions and circumstances which are to be taken into consideration during planning, such as: ec ama ces Pa fering ee em ratty ra ER GT joa Dacian nse joni barton 819 Changes in machinery and facilities Changes in personnel; deputies; shifts Transfer of production: changes of sup; Deviations which are concealed or difficult to detect ‘Technical features of the product (complexity) Product variants Batch size (large runs; small runs; one-offs) Production lines (varied production procedures) Non-capable manufacturing and measurement processes fee pre ac (a8 pea tb OO TTA peuuerans Tw Nie edoct Acct rogram: Anauel snag fea, corel i Ea Ec E Table 2: Practical assistance - example of an audit program = Supplier companies will need to modify the structure to suit their own products ~ e.g, th Broduct e-. the custome's end-product, sub-assembles and individual 14 42 Layout inspection somocampllancs of @ product with the customer's specications | Somronstrated by @ requalticaton check (ct. ISO/TS 18948), The check volved in this are set out in the production control plan, If (eualfcetion certification is required in association with the product the checks and tests involved must be integrated in the aust program, 43° Special CoP (conformity of production) checks [aS g basic rule manufacturer must ensure that his products conform wit {eg9i requirements. Using CoP checks, proof can be provided for aprons purposes, 44 Stipulations regarding the audit program {aking the sum of knowledge available and based on the audit program, the products to be audited and the associated objectives are derived tothe roduct audits A matrix can be used to support this process, such oe the pxample in Table 3. To simplify matters, product families can be drawn up By classifying the various targeted manner and repeat test a, audit results can be achieved in 19 can be avoided ip is example, al the input criteria are evaluated on an equel basis ang g Extent of an audit program ep then priritzed by adding up the evaluation fgures. The evalvaion ca eee Individual companies and additional input criteria can bin addition to the input criteria, the following should also be specified in the audit program : — Selected products from the overall product portfolio ‘and exient of the audit as part of the audit plan Considering thi A Sud eepae® exam, thé following conclusions can be drawn fr thy ~ For the 1.6 TD 77kW unit Program only for requalification to the production cor ntrol ~ No audits planned for the 1.9 FQ in the planning period mien ~ Product audits are planned for further products, ‘Audit program resources : (a Pieces forthe relevant product auits derived from the input crore. 6 9, © sublective quality’ of the passenger compartment: Deron rat Demonstrate the required noise level for unt XYZ when in oporavertAn Integral part of the audit program is the spectying of tho resourcos or ...) should be used as input data when drawing up the au. é selection of auditors and deciding on the extent of the audit tans, therequired, such as = = the products to be audited — the auditors carrying out the audit (qualifications to be defined if appropriate) — the rooms, checking equipment and checking/test facilities The various factors must be prioritized to mest company-specific requirements and must be documented 47 Implementing the audit program “The following are to be ensured when implementing an audit program = Approval of the auit program by the responsible authority = The departments affected must be informed = Coordination and time-pianning of audits = The necessary resources must be made a ~The audit must be carried out to the audi = Records of the audit activi »_~ Distribution of the’audit reports. — Execution of follow-up actions from auaits; cor 48 Monitoring and evaluating the audit program é The implementation of the audit program must be monitored at reasonal, intervals and reported to the responsible authorities. An evaluation of the audit program should, for example, take the followin into account : ~ Results and trends ~ Conformance with procedures ~ _Up-coming requirements and expectations from internal and externg customers ~ Audit program records or new audit practices ~ Equality of performance of diferent audit teams under comparable conditions: ‘on of compliance with input criteria such as customer ction, ete. Where evaluations from audit programs reveal deviations from th, company’s requirements, these must lead to corrective and preventin actions and the continuous improvement of the audit program, 20 ‘Audit plan Parad] Aust program | a6] Cary out Pe) produat aut ¥ Para. 7] Reporting 8 all the activities together with the it des he ausit plan generated from the audit program Tha resouroes required for carving outa product a fiming_andthe-numberof_random samples fo be {amet of te tostinspection planning ts also specitiod which checking method and equipment are to be used to check ity for drawing up the audit plan lies with the audit planner. 5.1 Characteristics to be checked and specifications _ ‘The audit program sets out the characteristics to be checked. These are specified more closely in the aut plan, for example in terms of: — materials / ee ‘" ~ appearance, odour and tactile feedback ("feel") / — functionality (@léctricalmechanica!) ~ ruggedness of the software ~ packaging 2 Further characteristics to be considered within the framework of reliabils 4 Requirements for taking parts & their identification or fs/endurance tests are, for example : 5.3.1 Taking parts = feacon tempor ted taken in accordance with the audit f the parts to be audited are (eae: peer nave undergone successfully the planned checks anc f ees g., intermediate checks; assembly progress checks or end-of- Requirements regarding characteristics to be checked are setautin.cumePrOoess ny ‘and therefore be in a condition where they can be forwarded techleal do Below. and must be taken Into account {Ing cer ont * the audit pian: — Drawings and other documents - oe ere te ae 7 "i cee 5.3.2 Identifying parts = Delivery agreements (regulations covering packing and markings ‘early identified so that they are = Production control plan; production sequence plans Process The een Sperations and so that the : rel Teeenei seals, measurement values taken can be allocated to the aucied Testnspecton ssecentons Ma eee ns aa bakon be asst Legal regulations 3.3 Transporting and packing parts 7 fs 7 rotected against damage during the audit and transpor Pas eins corosion, EMC, mechanical damage). Transporting the parts ea, 1 i adtinnuoncs the charectertis tobe checked 8.2 Checking methods / equipment and random samy ‘Appropriate and capable measurement and checking fac used when carrying out product audits. If possible these facilities shoul ot be those used for checking standard production. In this way it i: Possible to identify unsuitable and insecure equipment. 5.34 — Retuming parts for use Checks are to be carried out, sts of defects and li. sincple i possible to return audited products fo use, provid thar ble standards for He. Svaloctiog ee tay i characteristic are the same as those of new parts. {Te prects must nd samplos should be cS” ® "©9Ule returned to their original condition before they were 8 (0 sand samples should be carried out Conodion petecton sped pacagig). K must be ensired Hat the { deviate from the approvedireleased product. Defective pa The random cample size varies, depending on the checking method used, Pars do Hol Sevlals Tom the ooo a eogulations. the product and peripheral conditions. Consideration must be given to Production volumes, the production processes and their complexity, | security and legal requirements. Where qual samples should be use ensure constant and alignment check of the 23 22 54 Reference documents When carrying out a product audit, reference is made to all the techni documents in which details of the quality requirements are specified. | detail, these may include the fol - Drawings Specifications FMEA Production sequence plans; process descriptions: Test specifications ts of defects it samples and listings =u ~ Requirements covering the evaluation methods Evaluation / quality standards Material data sheets ‘Approved production deviations (special approvals) Records of customers’ expectations Standards Legal regulations (e.g., national legislation) Grading of defects, if appropriate (for example, into major and minor defects) with evaluations Delivery agreements Regulations covering the use of reference documents and the classification of defects (see Section 7.1: "Notes on classifying deviations and their evaluation’), 24 Carrying out product audits ‘Audit pian 3 i its set out is are cari out in accordance wit the requirement Pe at pe m:by specialy trained auditors (see Section 9 : "Qualification famer and eucitors). When en audit takes” pl lved are advised at short notice that products will be ents:

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