What is a process audit?
A process audit is an in-depth evaluation of a specific product or service process — from product development to series production, from supplier management to customer care — against its planned requirements. Where a system audit looks at the management system as a whole, a process audit goes inside a single process: are the inputs right, are the process parameters under control, are the people competent, are the equipment and environment suitable, do the outputs meet the requirements?
In the automotive supply chain, the reference method for process audits is the VDA 6.3 standard. We conduct our audits with the VDA 6.3 question catalogues and scoring methodology, or with question lists adapted to your sector and your requirements.
When should you commission a process audit?
- New projects and launches: to verify process maturity before series production and catch risks before they are carried into series.
- Customer audit readiness: to see where you stand before your OEM’s VDA 6.3 audit and close the gaps that would cost you points.
- Quality problems: to search systematically inside the process for the root cause of recurring returns, scrap or deviations.
- Supplier process audits: to evaluate the production processes of your critical suppliers on site, against your requirements and the VDA 6.3 methodology.
- Process improvement: to make efficiency and quality improvement areas visible through an independent pair of eyes.
Audit scope
Following the VDA 6.3 methodology, a process audit evaluates the process elements spanning the entire product life cycle: project management, planning and realization of product and process development, supplier management, series production and customer care. In the series production evaluation, every dimension is scored — from process inputs to process outputs, from staff competence to machine and equipment capability, from handling and storage to failure analysis.
At the end of the audit, your processes are graded, and every question is reported with an evidence-based evaluation and prioritized improvement areas.
Special processes
Special processes whose output cannot be fully verified afterwards — heat treatment, plating, welding, soldering and casting — are handled separately with the CQI assessment methodology. For that scope, see our Special Process Audits & CQI service.
How do we work?
- Scope definition: the processes, product groups and the reference method (VDA 6.3 or a custom question list) are agreed.
- Preparation: product and process documentation is reviewed; the audit plan and question lists are prepared.
- Field audit: every question is scored with evidence gathered through observation on the production line, interviews with process owners and record review.
- Reporting: the grading, findings and prioritized action recommendations are presented in the closing meeting.
- Follow-up: the effectiveness of actions is verified; on request, a follow-up audit measures the improvement.
Frequently Asked Questions
Is VDA 6.3 mandatory for a process audit?
No. VDA 6.3 is the de facto standard in the automotive supply chain, but outside automotive we conduct the audit with question lists built around your requirements and the relevant standards. If you are an automotive supplier and your OEM requires VDA 6.3, the audit follows that methodology exactly.
Can a process audit be combined with a system audit?
Yes, and it is a popular combination: the system audit scans the management system as a whole, while the process audit examines the critical production processes in depth. For the system dimension, see our System Audit page.
What qualifications do your auditors hold?
Our audits are performed by VDA certified process auditors with more than 20 years of field experience in the automotive and aerospace sectors.
Request a Quote
To plan a process audit for your own processes or your suppliers, get in touch with us; we will prepare an audit plan and a quote tailored to your scope.