Vda 2 PDF
Vda 2 PDF
Vda 2 PDF
Quality Management
6
in the Automotive Industry
QM - Systemaudit Part 2
- Services -
Based on DIN EN ISO 9001, 9002, 9004-1 and DIN EN ISO 9004-2
3
Quality management
System audit
- Services -
Referenced standards
Copyright protection
The works including all its parts is copyright protected. Any utilisation
outside the tight limits of the copyright protection law without consent of
VDA is not permitted and liable to prosecution. This concerns in particular
reprotections, translations, micro-fiches and the storage and processing on
electronic systems.
3
ISSN 0943-9412
Copyright 1999 by
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Preface
The trend towards total service provision takes place before the background
of customers more and more frequently using the tougher competition on
the domestic as well as on the international supplier markets for their own
benefit.
This also more and more influences the person and load transport vehicle
segment within the automotive branch. The cost-benefit-ratio no longer is
the sole decisive factor, but the quality of the rendered services today plays
a role of growing importance.
DIN ISO 9004-1 and DIN ISO 9004-2 as a guideline as well as the textual
versions of the DIN EN ISO 9001 resp 9002 have been the platform on
which the working team prepared the VDA-paper volume 6, part 2.
Assuming that each company has developed its own quality management
system adapted to its size, branch, and product/service, or is presently in
the state of implementing it, the VDA-working team started their conside-
rations with how to monitor the ,,Quality standard of the German automotive
industry" (VDA 6) with the help of quality audits close to everyday practise.
The overall audit strategy for the automotive industry as defined by the
committee QUALITYMANAGEMENT looks as follows:
5
There is an agreement that this paper is going to be divided into a
Part U: Management
Part P: Product/Service and Process
while the Part U is mostly congruent with the statements of the VDA-Paper
Volume 6, Part 1, ,,QM-system for material products". The element Z1 here
however is a mandatory part.
The Part P is oriented along the process chain from market research to final
customer services.
We very much hope that this paper of the VDA-6 series too will be able to
reach the success of VDA-paper volume 6, Part 1, and would like to heartily
thank the contributing companies and their employees for their efforts in the
preparation of this VDA-paper.
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Contents Page
Preface 5
1 Introduction 11
1.1 Quality management and Service 11
1.2 Product quality and service quality 11
1.3 Chances and Risks 12
1.4 Hints on auditing 13
4 Terms 27
4.1 General Terms according to DIN EN ISO 8402/1995 (Excerpt) 27
#.1.1 Unit 27
#.1.2 Process 27
#.1.3 Procedure 28
#.1.4 Product 28
#.1.5 Service 29
#.1.6 Service providing 29
#.1.7 Organization 29
#.1.8 Organizational structure 29
#.1.9 Customer 30
#.1.10 Supplier 30
7
4.2 Quality-related terms according to DIN EN ISO 8402/1995
(Excerpt) 30
#.2.3 Quality Requirements 30
#.2.15 Testing 31
#.2.17 Verification 31
#.2.18 Validation 32
#.2.19 Proof 32
8
Part P: Product/Service and Process 82
07 Market research 82
08 Development 86
09 Service preparation 91
10 Promotion and marketing 95
11 Sales/Service agreement 100
12 Purchasing 104
13 Service providing 110
14 Customer services (After-sales service, product observance) 118
15 Analysis and improvement of services 122
16 Control documents and data (definitions) 127
17 Control quality records (proofs) 131
9 Literature 141
Reference sources 144
Literature - company specific 145
12 Appendix 149
12.1 Modifications 149
12.2 Comparison table sheets 149
12.2.1 Comparison matrix VDA 6.2/DIN EN ISO 900194 149
12.2.2 Comparison matrix DIN EN ISO 900194 /VDA 6.2 154
9
10
1 Introduction
From any vehicle, the customer expects a constantly high product quality,
and he also has great expectations concerning the service provision.
The service provider has to win the customer's trust and to maintain it
permanently. Yet customers in the past have experienced a rising quality of
life standard. So the requirements they raise towards services of the auto-
motive industry are higher. If his expectations are not met, the customer will
wander off towards another service provider.
Services are such processes in which the internal or external customers are
directly or indirectly participating in the process, e.g. when a car is
purchased or tyres are exchanged. In this case, the quality of the service is
assessed directly by the customer.
11
Hence the service quality is clearly distinguished from the product quality.
While material products usually can be touched up after sales for cus-
tomer's satisfaction, poor services are often also the last services for a
customer as he is prone to wander off, mostly without giving reasons.
For example: are errors damned on principle or turned into the basis for
measures of improvement (e.g. learning organization)?
Does the extent of documentation satisfy the demands for stable processes,
or does it merely refine bureaucracy? Do the measures only aim at the
short-term good rating in the next audit to come, (or receipt of certificate/
record), or do they also aim at a ,,return on investment"?
12
1.4 Hints on auditing
QM-system audits for services in the automotive practise become more and
more important.
Part U: Management
Part P: Product/Service and Process.
13
2 QM-system according to standard dass DIN EN ISO 9000
The standard series DIN EN ISO 9000 has normative character within the
European Union (EU) and within the EFTA. The German version is identical
for Austria, Germany and Switzerland.
Quality and customer satisfaction are major issues to which more and more
attention is drawn all over the world. This part of the ISO 9004 takes this
awareness into account and wants to encourage organizations and corpo-
rations to design the quality aspects of their activities which lead to services
more effectively.
14
This part of the ISO 9004 can be applied to a newly offered or modified
service in the context of the development of a quality management system.
It can also be directly referred to for implementation of a quality manage-
ment system for already existing services. The quality management system
encompasses all processes which are required for rendering an effective
service, starting from marketing through to final delivery. It also comprises
the analysis of the services delivered to customers.
The concepts and principles contained in this part of the ISO 9004 are
suitable for large as well as for small organizations. Even though a small
service providing organization won’t have or need the complex structures
required by larger corporations, the same principles apply. The difference is
only in size. In most cases, the customer will be the final recipient of any
service outside the organization. However the customer might also fre-
quently be within the own organization, which is particularly so in larger cor-
porations in which the customer can be present in a subsequent stage of
the delivery process. Even though this part of the ISO 9004 has been
written basically with reference to external customers, it can also be applied
to fulfill completely quality requirements from internal customers, too.
Extent and depth of the presentation of the QM-system may depend on the
kind of the products/services to be delivered, the used technologies, and the
size of the corporation to be rated.
The following paragraphs have been taken from the national preface and
the introduction to the DIN EN ISO 9001: 1994-08, which is very
appropriately formulated as follows:
Winning trust into the suppliers' ability to fulfill defined minimum require-
ments to his quality management system today more and more becomes a
prerequisite for the cooperation between customer and supplier. This trust
can be established by specification of the quality management system
15
towards the customer or an authorised body. All systematic trustfunding
activities according to the DIN EN ISO 8402 are denominated as quality
assurance or quality management specification (in short: QM-specification).
The standards DIN EN ISO 9001, DIN EN ISO 9002 and DIN EN ISO 9003
each contain one model for quality assurance/QM-specification. Only these
three standards of the DIN EN ISO 9000-class are foreseen for specification
purposes. These standards show a way of how to establish trust in a
supplier's ability.
1
According to EN ISO 8402,1.4 product can also include service.
16
ISO 9001 Quality management systems -
Model for quality assurance/QM-specification in design,
development, production, assembly and maintenance.
To be applied if the supplier/contractor has to assure the
fulfillment of defined requirements during design², develop-
ment, production, assembly and maintenance.
Model ISO 9003 is not referred to within the application range of the VDA.
17
3 QM-system audit - Services -
- management responsibility
- quality management system
- training, personnel
- financial considerations concerning QM-systems
- product safety
- interface to the customer
- analysis and improvement of service
- corporate strategy (e.g. EFQM)
18
Once a system audit of a service provider's QM-system according to
section 3.4 has proven that the service meets the requirements, recurring
QM-system audits have to be performed in appropriate defined intervals.
For the individual elements, some references are made under the
header requirements/explanations, which are assessed with different
intensity for the individual questions.
19
Some questions concerning the QM-system may only be answered along
the evaluation of the service to be rendered resp. of the product to be
delivered and/or the applied procedures. This could require a separate
assessment (service rating, service audit).
The procedure described below refers to the focuses for the planning/exe-
cution of an audit by the auditor in order to assure the correct audit process.
This also necessitates the early involvement of the audit partner.
Steps Focus
20
3.4 Rating and assessment
Defined in the
QM-system completely mostly*) no yes/no
Effectively proven in
practice yes no mostly*) no
Number of points
scored 10 8 6 4 0
21
Rating
The element rating EE results as percentage of the total points score of all
applications questions referring to the total number of possible points of all
applicant questions. If all questions applicant to one QM-element are rated
with 10 points, then the degree of fulfillment is EE 100 %.
22
3.4.2 Total audit result rating
For the two parts U (management) and P (service process) first the
fulfillment degrees EU and EP have to be calculated. They are calculated as
average values of the fulfillment degrees of the correspondingly audited
QM-elements:
CE + EP
EGES = — — — — — in [%].
2
The rating system can also be applied when QM-elements or questions are
added or cancelled.
Different from the calculation of EGES in the VDA-paper volume 6 part 1 here
part U is not weighed additionally higher. Then given ratio of the QM-
elements (7 to 11) here already results in a higher weighing than in the
VDA-paper volume 6.
23
3.4.3 Classification
*) Remarks:
1. Audited companies which reach a total fulfillment degree of more than 90 % resp. 80 %
but in one or several QM-elements only reach a fulfillment degree of below 75 % will be
degraded from A to AB resp. from AB to B.
2. If items the non-fulfillment of which may have decisive impact on the service quality are
rated with zero points, then the audited company may be degraded from A to AB resp.
from AB to B.
3. Only one degradation to 1 or 2 is permitted.
4. Degradations have to be reasoned in an explanation sheet.
The results of the QM-system audit according to the audit parts U (manage-
ment) and P (Service process) have to be represented according to the
sample form sheets (main section 8). The survey of results per QM-element
are entered in the sheet "Survey of results".
24
3.6 Final discussion and report
In a final discussion of the QM-system audit the auditor informs the mana-
gement about the weaknesses requiring corrective measures. These are
represented in a survey sheet „corrective measures“. The survey on the
QM-system audit result is supplemented by the auditor with a report which
details the observed weaknesses.
25
26
4 Terms
#.1.1 Unit
#.1.2 Process
27
#.1.3 Procedure
#.1.4 Product
Remark 1: The term product can include service (1.5), hardware, process
technology products, software or combinations of those.
28
#.1.5 Service
Remark 3: Supply or use of tangible products (1.4) may form part of the
service provision.
#.1.7 Organization
29
#.1.9 Customer
#.1.10 Supplier
30
Remark 2: The term "requirement" comprises market, contractual, and
also internal requirements of a certain organization (1.7).
These can be developed, detailed and upgraded in the various
planning stages.
#.2.15 Testing
#.2.17 Verification
31
#.2.18 Validation
Remark 2: Validation usually takes place at the finished product and under
defined operating conditions. It may become necessary in
earlier stage.
#.2.19 Proof
32
#.3.6 Quality system (Quality management system)
Document defining the quality policy (3.1) and describing the QM-system
(3.6) of an organization (1.7).
a) quality policy;
b) responsibilities and authorisations (competences) as well as
reciprocal interrelations of staff who are managing,
executing,
testing or assessing quality-oriented activities;
c) the procedures (1.3) of the QM-system (3.6) and pertinent
instructions;
d) specification of testing, updating and administration of the
manual.
33
Remark 3: Comprehensiveness and format of QM-manuals may differ in
order to meet the organizations’ requirements. They may
contain more than one document. Depending on the purpose
of the manual, a denomination may be used, e.g. „Quality
Assurance Manual“/“QM-Specification Manual“.
34
#.4.10 Quality audit record
A fact noticed during a quality audit (4.9) and certified by proof (2.19).
4.5.1 System
35
4.5.2 Method
36
5 Comparison matrix of the section numbers for corresponding
subjects
37
6 Structure of questions and number of questions per QM-Element
Page No. of
questions
U Management
01 Management responsibility 41 6
DIN EN ISO 9001, Section 4.1
DIN ISO 9004-2, Sections 5.2, 5.3, 6.4
02 Quality management system 49 4
DIN EN ISO 9001 Sections 4.1, 4.2, 4.3
DIN ISO 9004-2, Sections 5.2, 5.4
03 Internal quality audits 54 4
DIN EN ISO 9001, Section 4.17
DIN ISO 9004-2, Sections 5.4, 6.2
04 Training, personnel 59 6
DIN EN ISO 9001, Section 4.18
DIN ISO 9004-2, Sections 5.3, 5.4
05 Financial considerations of QM-systems 64 4
DIN EN ISO 9004-1, Sections 6.1, 6.2, 6.3
06 Product safety 69 5
DIN EN ISO 9004-1, Section 19
Z1 Corporate strategy 75 5
Total number of questions (Part U) 34
38
Page No. of
questions
P Product/Service and Process
07 Market research 82 5
DIN EN ISO 9001, Section 4.4
DIN ISO 9004-2, Sections 5.5, 6.1, 6.2
08 Development 86 5
DIN EN ISO 9001, Section 4.4
DIN ISO 9004-2, Sections 6.1, 6.2
09 Service preparation 91 4
DIN EN ISO 9001, Sections 4.3, 4.4, 4.10
DIN ISO 9004-2, Sections 6.2, 6.3
10 Promotion and marketing 95 6
DIN ISO 9004-2, Section 6.1
11 Sales/Service agreement 100 5
DIN EN ISO 9001, Section 4.3
DIN ISO 9004-2, Sections 5.4, 5.5, 6.1
12 Purchasing 104 7
DIN EN ISO 9001, Section 4.6, 4.10, 4.13
DIN ISO 9004-2, Section 6.2
13 Service providing 110 7
DIN EN ISO 9001, Sections 4.7, 4.8, 4.9, 4.10,
4.11, 4.12, 4.13, 4.15
DIN ISO 9004-2, Sections 6.2, 6.3
14 Customer services 118 4
DIN EN ISO 9001, Sections 4.10, 4.14, 4.19
DIN ISO 9004-2, Sections 5.4, 5.5, 6.3, 6.4
15 Analysis and improvement of service 122 5
DIN EN ISO 9001, Sections 4.14, 4.19, 4.20
DIN ISO 9004-2, Sections 6.3, 6.4
16 Control documents and data 127 4
DIN EN ISO 9001, Sections 4.5, 4.16
DIN ISO 9004-2, Section 5.4
17 Control quality records 131 4
DIN EN ISO 9001, Section 4.16
DIN ISO 9004-2, Sections 5.4, 6.4
39
7 Questionnaire to the QM-system audit
- Services -
Structure
1. Question
2. Definition
If necessary, the terms used in the question for which no definition was
given are explained for better understanding.
Explanation of terms
If necessary, those terms used in the question for which no definition was
given are explained for better understanding.
3. Requirements/Explanations:
Note: The auditor has to assess the definition and the effectiveness
of the QM-measure for each applicant item.
40
Part U: Management
01 Management responsibility
DIN EN ISO 9001, Section 4.1
DIN ISO 9004-2, Sections 5.2, 5.3, 6.4
Reference
DIN EN ISO DIN ISO
9001 9004-2
01.1 Has the quality policy been defined by the 4.1.1 4.2
management and made known to all levels?
01.2 Have quality targets been in the scope of 4.1.1 4.3.1
corporate planning resp. in the quality policy,
are the results monitored?
01.3 Is a continuous improvement process part of -- --
the quality policy?
01.4 Have the required means been provided by 4.1.2.2 5.2.4
the corporate management?
01.5 Has the management appointed a QM- 4.1.2.14. 5.2.2
manager? Are his duties, authorisation and 1.2.3 5.2.3
responsibilities defined?
01.6 Does management regularly assess the 4.1.3 5.5
effectiveness of the QM-system?
41
01.1 Has the quality policy been defined by the corporate manage-
ment and made known to all levels?
Definition:
Requirements/Explanations:
Measurable quality targets have to be derived from the quality policy (see
question 01.2).
42
01.2 Have quality targets been defined in the scope of corporate
planning resp. in the quality policy, and will the results be
monitored?
Term definition:
Requirements/Explanations:
43
d) Superior targets
44
01.3 Is a continuous process of improvement part of quality policy?
Requirements/Explanations:
Note: Links to item 01.2 are possible. The used working methods can
be chosen per corporation.
45
01.4* Have the necessary means be provided by the corporate
management?
Requirements/Explanations:
Note: The evaluation of this item can only be finally made once the
whole QM-system has been made transparent by the audit and
it has been determined that all necessary means are available.
46
01.5 Has the management appointed a QM-representative and
have his tasks, authorities been defined?
Term definition:
Requirements/Explanations:
47
01.6 Does the board of directors regularly assess the effective-
ness of the QM-system?
Definition:
Requirements/Explanations:
The assessment results from the comparison of the determination with the
quality policy targets and usually leads to general preventive and corrective
measures.
48
02 Quality management system
DIN EN ISO 9001, Sections 4.1, 4.2, 4.3
DIN ISO 9004-2, Sections 5.2, 5.4
Reference
DIN EN ISO DIN ISO
9001 9004-2
49
02.1 Has the QM-system been described in a quality system
manual or similar documentation?
Definition:
Document defining the quality policy and describing the QM-system (quality
management system) of any organization.
Requirements/Explanations:
The manual has to state the approval of the board of directors, the date of
effectiveness, resp. the revision service. The responsibilities for upgrading,
the revision service and distribution list have to be defined. The main pur-
pose of the QM-manual is to define the structure of the QM-system and at
the same time serve as permanent reference for its implementation and
maintenance.
50
02.2 Does the QM-system encompass all units, levels and emplo-
yees of the corporation?
Definition:
Requirements/Explanations:
- cross-unit activities
- corresponding trainings, presentations, publications
- unit-specific targets for quality improvement
- competence charts.
Job descriptions and organigram charts serve - among other things -to
support the employees, to provide clarity at interfaces, and to give evidence
of the task. They make the organization transparent, facilitate qualification
and recruitment of staff as well as promote motivation and readiness to
make decisions.
Term definition:
51
Requirements/Explanations:
Definition:
52
Remark:
Requirements/Explanations:
53
03 Internal quality audits
DIN EN ISO 9001 Section 4.17
DIN ISO 9004-2 Sections 5.4, 6.2
Reference
DIN EN ISO DIN ISO
9001 9004-2
54
03.1 Is the staff (auditors) qualified for execution of internal qua-
lity audits and independent of the units to be audited?
Definition:
Term definition:
"Quality auditors" (see DIN ISO 10011, Part 2) have to be impartial and free
of influences which might impair their objectivity.
The staff entrusted with carrying out audits have to be independent of the
units on which they report.
Requirements/Explanations:
Auditors have to be qualified to carry out and supervise quality audits.
Following aspects should be considered as particularly relevant:
- Qualification according to DIN ISO 10011-2
- Knowledge and understanding of the standards which form the
basis for audits of quality systems (DIN EN ISO 9000-9004,
VDA-Paper volume 6, Part 2)
- Methods for assessment by means of evaluation, interviews,
rating and reporting (e.g. auditor training)
- Skills required for supervision of a quality audit such as
planning, organization, communication and supervision
- Experiences in quality management and quality techniques
- Knowledge of the work flows and processes to be audited
- Soft skills such as integrity, judgement capability, analytic skills,
impartiality
- Maintaining skills with certificates.
The requirement profile for auditors has to be defined. This profile has to be
proven in acceptable manner.
55
03.2 Will the elements belonging to the QM-system be internally
audited and assessed according to an audit-plan?
Term definition:
An „audit plan“ (according to DIN ISO 10011-1) defines the different audits
with schedules and the units to be audited. This audit is the systematic
review of all QM-elements concerning their effectiveness, compliance, and
up-to-date-ness.
Requirements/Explanations:
- Audit target
- Reference documents (standards, QM-manual, processing
instructions etc.)
- Units to be audited
- Audit process
- Questionnaire
- Schedule
- Auditors/audit team
- Reporting with distribution list
- Tracking the measures.
56
03.3 Will the performance and process requirements be audited
internally according to an audit plan?
Term definition:
A „service audit“ serves for rating the compliance of the service perfor-
mance with the defined service quality requirements. This can necessitate
the testing of products.
A „process audit“ serves for testing whether the services are up to fulfill the
quality requirements and if the process is mastered and suitable.
Requirements/Explanations:
Audit plans have to be defined for services and processes and should
contain following information:
- Audit target
- Reference documents
- Services and processes to be audited
- Audit process
- Questionnaire
- Schedule
- Auditors
- Reporting with distribution list
- Tracking the measures.
During these audits the suitability of the working conditions and environment
should also be reviewed (see also item 14.6).
57
03.4 Do discrepancies lead to corrective measures, will these be
documented and their effectiveness be monitored?
Definition:
Task carried out for elimination of the causes of an occured error; defective
or other unwanted situation in order to prevent its recurrence.
Requirements/Explanations:
- Discrepancies
- Non-fulfillment of standard requirement
- Assembly is unsuitable to reach targets
- Activity is not conform to the instruction
- lnstruction is not actually complied with
- Rate/weigh discrepancies
- Image
- Risk/product safety
- Cost-effectiveness
- Corrective measures
- Responsibilities/Deadlines
- Testing for effectiveness
- Reporting
- Adjusting documentation (such as QM-system).
58
04 Training, personnel
DIN EN ISO 9001 Section 4.18
DIN ISO 9004-2 Section 5.3
Definition:
Reference
DIN EN ISO DIN ISO
9001 9004-2
59
04.1 Is steady improvement of the supervision for the employees
achieved?
Term definition:
Requirements/Explanations:
Evidence can be given e.g. by specified improvements during the past two
years, or by means of interviewing employees.
Term definition:
Qualification means:
Requirements/Explanations:
60
The qualification of employees has to be defined, e.g. in:
- Requirement profiles
- Job descriptions
- Function descriptions.
Term definition:
Requirements/Explanations:
61
04.4 Are performance targets agreed with the employees?
Are they permanently reviewed, target achievement assessed
and measures derived from noticed discrepancies?
Requirements/Explanations:
All employees on all levels performing quality-related tasks should be
involved. Between employees and superiors achievable performance
targets have to be agreed and proven. These targets have to be derived
from the unit targets/corporate targets. An assessment of target achieve-
ment has to take place regularly in discussions with the employees, and in
case of discrepancies (both positive or negative) measures have to be
defined. The contact between superior and employee is thus intensified.
Among these aspects are among others:
- Definition of performance indicators
- Derivation of departmental targets from unit targets/corporate
targets
- Regular discussions with employees (at least annually).
Term definitions:
As „commitment“ we understand the individual employees' readiness to
service and his attitude towards the corporation as shown also in his moti-
vation.
Requirements/Explanations:
Such an improvement can be achieved e.g. by:
- Promotion of overall quality consciousness
- Transparency of performance results
- lncentive systems for employees
- Proposal system for improvements proposed by employees
- Quality circle
- Trainings.
62
04.6 Is employees’ satisfaction evaluated and are measures
derived from this assessment?
Requirements/Explanations:
63
05 Financial considerations on quality management systems
DIN EN ISO 9004-1 Section 6
Reference
DIN EN ISO DIN ISO
9001 9004-2
64
05.1 Is there a procedure for financial reporting on the effective-
ness of the QM-system?
Requirements/Explanations:
The known methods do not exclude others or their adjustment and/or com-
bination.
The corresponding procedure, the method and its cost structure (See items
05.2 through 05.4) have to be represented (e.g. with instructions, distributor
records, cost center and accounts plans, summarising all financial expen-
ses for the corporate management).
Qualitv-related costs
- error prevention
- tests
- internal and external errors
- conformity costs
- non-conformity costs
65
Amount, process and analysis of the expenses in relation to errors and error
causes have to be reported to the corporate management.
The corporation has the duty of recording financial key figures indicating the
efficiency of the QM-system, and to represent and analyse them in terms of
cause and time, introduce corrective and preventive measures and to track
its effectiveness.
Term definition:
Requirements/Explanations:
For the subsequent period quality and cost targets have to be defined.
therefore, e.g. the following questions have to be answered:
66
05.3 Are there records of internal losses due to insufficient quality
(non-conformity)?
Term definition:
Requirements/Explanations:
- Damages
- Repairs
- Re-acquisition
- Reduced values
- Non-scheduled tests
- Storage-/Standing costs
- Problem examinations
- Breakdown times due to errors
- Failure to meet planing defaults
- Value modifications (higher value than planned or agreed).
67
05.4 Are there records of external losses due to non sufficient
quality (non-conformity)?
Term definition:
„External losses“ are material and immaterial losses occuring after deliver
due to insufficient quality.
Material losses are costs for errors resulting from the non-fulfillment of
quality requirements by a product/a service after delivery (e.g. rejects,
touch-up and repairs, warranty services and return shipments, direct cost
and compensations, costs for calI-back actions, costs of product liability).
Typical immaterial losses are e.g. lost future sales due to unsatisfied
customers.
Requirements/Explanations:
- Image loss
- Loss of customers due to their dissatisfaction.
68
06 Product safety
DIN EN ISO 9004-1 Section 19
Reference
DIN EN ISO DIN ISO
9001 9004-2
69
06.1 Are the principles of product Iiability known in the corpo-
ration?
Definition:
Remark: The legal and financial effects of product liability depend on the
respective jurisdiction.
Hints: The paragraphs 823, 831 BGB (German Civil Code) do not
expressly regulate the matters of product liability. The basis is
rather the implicit safe goods traffic obligation for producers,
suppliers, traders who bring goods into commercial traffic. The
requirements of caution and care can be classified into follo-
wing categories according to the jurisdiction:
- Development errors
- Construction errors
- Fabrication errors
- lnstruction errors
- Product observance errors.
Requirements/Explanations:
Product safety defects could lead to liability claims against the supplier.
Knowledge on the product liability principles therefore is required for all
employees who give relevant instructions on product safety.
70
Principles are:
Term definition:
Requirements/Explanations:
71
- A call-back system warranting appropriate opportunities to
tracking and call-back of unsafe products
- An early-warning-system for call-back risks.
Term definition:
Requirements/Explanations:
The specifications for service provision should contain all legal regulation as
well as relevant working safety, health protection and environmental
protection requirements.
72
06.4 Does the Service provider meet his obligation to instruct?
Term definition:
Requirements/Explanations:
Concerning the obligation to instruct, the jurisdiction requires that the pro-
ducts are accompanied by operating manuals and handling instructions.
Besides this mere obligation to instruct, warnings have to be issued against
possible dangers which might result from the product or wrong usage of the
product.
73
06.5 Are people warned against possible dangers in the plant
which are not evidently obvious?
Term definition:
Requirements/Explanations:
74
Z1 Corporate strategy
Reference
DIN EN ISO DIN ISO
9001 9004-2
75
Z1.1 Does the corporation have a strategic business plan con-
taining aspects of costs, distribution, quality and do on?
Terms definition:
Requirements/Explanations:
a) Aspects of cost
- Financial and costs planning (investments, personnel and
material costs)
- Cost targets.
b) Aspects of distribution
- Market data
- Turnover/sales targets
- Criteria of customer satisfaction (see item Z1.4)
d) Aspects of development
- Development projects
- Analyses of competition performance
76
All aspects should be:
Term definition:
Requirements/Explanations:
- Profit
- Cash flow
- Turnover
- Value added
- Capital of the corporation
- Liquidity
- Dividends
- Long-term shareholder value.
77
These figures in practice are stated partially in absolute figures, partially as
the ration per capital unit, or per headcount.
- Market shares
- Exploitation of the plant
- Touch-ups and repairs
- Variability of products/services
- Achieved customer satisfaction
- Image key data
- Due and on time deliveries
- Order processing time
The measured units are outlined along the corporate strategies and the
entrepreneurial targets and defaults. They contain measuring units
indicating the company’s efficiency and cost-effectiveness and decisive for
the long-term, lasting corporate success.
The data have to be analysed/evaluated and the results must lead to
corrective measures (e.g. action plans).
Note: Only the installed system, not the result has to be audited.
78
Z1.3 Are corporate performance data compared with results from
benchmarking or other methods, and are corrective measu-
res introduced if necessary?
Requirements/Explanations:
Evaluation, analysis and benefit of corporate performance with data of com-
petitions or other companies by means of benchmarking should given hints
as to e.g.:
- Productivity
- Cost-effectiveness
- Quality status
- Performance.
79
Z1.4 Is a procedure allowing to measure customer satisfaction and
to record changes installed?
Requirements/Explanations:
- Method application
- Recognition frequency
- Data evaluation and representation
- Interpretation of trends
- Competences
- Distribution list
As far as possible, not only the direct customer, but also the final user
should be involved.
Note: Only the installed procedure has to be audited, not the result.
80
Z1.5 Is employees’ satisfaction a corporate management princip-
les, and is it continuously maintained?
Term definition:
Requirements/Explanations:
Note: Only the installed system has to be audited, not the result.
81
Part P: Product/Service and Process
07 Market research
DIN EN ISO 9001, Section 4.4
DIN ISO 9004-1, Sections 5.5, 6.1, 6.2
Reference
DIN EN ISO DIN ISO
9001 9004-2
82
07.1 Have responsibilities and competences for market research,
survey and analysis been defined?
Requirements/Explanations:
The function market research, survey and analysis has to determine the
requirements and expectations towards the offered services. To this end, a
flow chart has to be defined in which all involved functional and organi-
zational units are involved with their overall or partial responsibilities.
Requirements/Explanations:
Requirements/Explanations:
83
Exemplary tasks are:
- Planning how, who and by whom interviews are held, the kind
of questions to be asked, time, place, number of interviewees,
etc.
- Results of the survey such as specific customer requirements/
customer expectations have to be made known to the manage-
ment and the concerned bodies.
Term definition:
Benchmarking is the systematic search for best practise by means of direct
comparison with a benchmarking partner. This comparison leads to
standard „benchmarks“, along which the own performance can be rated
resp. audited. The aim is improving the own products/services and prac-
tises.
Requirements/Explanations:
Execution and evaluation of benchmarking and competitive analyses have
to be specified as well as the process of deriving measures from their
results.
(See also item Z1.3)
84
07.5 Are additional products/services derived from market analy-
ses and offered on the market?
Requirements/Explanations:
It has to be specified how the information gathered from analyses are
- edited
- made known to the concerned bodies
- leading to specification of new or additional products/services
- implemented and introduced
- reviewed concerning their effectiveness
- and in CASE defaults are not met, corresponding actions are
taken.
85
08 Development
DIN EN ISO 9001 Section 4.4
DIN ISO 9004-2 Sections 6.1, 6.2
Reference
DIN EN ISO DIN ISO
9001 9004-2
86
08.1 Have responsibilities and competences for service develop-
ment been defined?
Requirements/Explanations:
For the development plan, current milestone-plans, flow charts etc. have to
be presented with detailed plans representing all activities from conception/
order through to introduction. The systematic tackling of planned tasks (pro-
ject planning) has to be assured. A responsible project manager and all
involved units with their tasks have to be stated. A central monitoring of pro-
ject progress has to be assured (target-actual-comparison). Monitoring has
to comprise compliance with all defined targets, such as:
- tasks
- competences
- responsibilities
- deadlines
- means.
Definition:
The specification defines HOW and WHAT FOR a task has to be solved.
87
Delineafion (DIN 69905):
The delineation defines HOW and WITH WHICH MEANS the requirements
shall be fulfilled.
Requirements/Explanations:
Definition:
88
Remark 2: A specification should refer to drawings, patterns or other
pertinent documents, or contain same, and should also state
means and criteria with which conformity can be tested (2.9).
Requirements/Explanations:
Requirements/Explanations:
89
08.5 Is it assured that modifications during development activities
are documented in a uniform and traceable manner?
Requirements/Explanations:
90
09 Service preparation
DIN EN ISO 9001 Sections 4.3, 4.4, 4.10
DIN ISO 9004-2, Sections 6.2, 6.3
Reference
DIN EN ISO DIN ISO
9001 9004-2
91
09.1 Is implementation of the requirement catalogue into the
service process assured?
Definition:
Requirements/Explanations:
Cyclic reviews shall check if the defined requirements are actually complied
with.
The representatives of all functions that have an impact on the service quali-
ty should participate in these reviews.
Requirements/Explanations:
92
Definitions of following aspects have to be considered among others:
- Processes in manuals
- Quality criteria
- Acceptance criteria for the services
- Time schedule for the launching stage
- Purchasing of products, materials, elements, services, tools
and equipments.
Requirements/Explanations:
The procedures for testing, recording and monitoring for audit purposes of
the product/service quality have to be defined in processing instructions.
- Test procedures
- Product-/Service specifications
- Checklists
- Documentation of results
- Verification by spot-checks.
93
09.4 After the product/service preparation is over, do review and
release take place?
Requirements/Explanations:
94
10 Promotion and marketing
DIN ISO 9004-2 Section 6.1
Reference
DIN EN ISO DIN ISO
9001 9004-2
95
10.1 Are there regulations for responsibilities/competences,
planning and execution of promotion actions?
Requirements/Explanations:
Requirements/Explanations:
96
Active customer contact also is to be considered. This means for example:
Requirements/Explanations:
These requirements refer to the „Corporate ldentity" (Cl) and also comprise
communication with existing and potential customers. Depending on the
kind of products/services, availability, design of the environment order-
liness/cleanliness and appearance of the employees also have to be con-
sidered.
Requirements/ExpIanations:
97
This measure shall positively influence the quality of promotion and should
prevent the possible errors listed hereafter, such as:
Requirements/Explanations:
or similar measures.
98
10.6 Is the competence of the service provider part of the pro-
motion actions?
Requirements/Explanations:
99
11 Sales/Service agreement
DIN EN ISO 9001 Section 4.3
DIN ISO 9004-2 Sections 5.4, 5.5, 6.1
100
11.1 Are there definitions and procedures defining the methods
and responsibilities for proposal and contract review (for all
types of contracts)?
Requirements/Explanations:
The service provider has to define the procedure and responsibilities for all
kinds of possible contracts (sales, rental, leasing, service agreements and
so on) in a proper manner. This definition, or a similar document, must
show the competences of the employees entrusted with the execution.
The focus is on an unambiguous feasibility check, i.e. the procedure has to
assure that possible weaknesses (being unable to fulfill requirements etc.)
are recognised before a contract is agreed. lt also has to be considered
whether further departments within the corporation or at the customer's
have to be contacted.
Requirements/Explanations:
The applicant requirements should be stated in writing while the form of the
documentation should be adjusted to the value and scope of the service to
be provided.
101
11.3 Are inquiries, proposals, contracts checked for completeness
and feasibility and then released?
Requirements/Explanations:
Requirements/Explanations:
102
11.5 Have procedures and responsibilities for contract reviews
been defined?
Requirements/Explanations:
The QM-system has to define the proceedings and the responsibility for
execution of contract amendments. Recording of evidence has to be adjus-
ted to the value/extent of the service, and can be made in form of a memo
or if necessary by a new contract text or alternatively as an amendment to
the existing contract.
103
12 Purchasing
DIN EN ISO 9001 Sections 4.6, 4.10, 4.13
DIN ISO 9004-2 Section 6.2
Reference
DIN EN ISO DIN ISO
9001 9004-2
104
12.1 Is there a regulation of competences and an audit process for
suppliers/subcontractors of products/services?
Requirements/Explanations:
- QM-manuals
- Processing instructions
- Organisation instructions or similar documents.
This determination has to show the proceeding and the responsibility for the
execution as well as the decision making competences.
For the first qualification and the current audit, appropriate procedures/
records such as e.g.:
- Checklists
- Requirement profiles
- Simple rating procedures.
105
12.2 Is there a survey of approved suppliers/subcontractors?
Requirements/Explanations:
The corporation must have installed a systematic which assures that pur-
chases can only be made from approved, sufficiently qualified suppliers/
subcontractors.
Requirements/Explanations:
106
Concerning eventually necessary modifications of the purchasing process,
such as modifications of specifications or changes of the scope of delivery
the competences for coordination/handling have to be defined under con-
sideration of feasibility. If necessary, also internal/external interface regula-
tions have to be considered.
Requirements/Explanations:
Requirements/Explanations:
107
This can be done by means of e.g.
Definition:
Requirements/Explanations:
The supplier must have a procedure for how to handle defectives or non-
conformities.
108
The subcontractor has to be contacted quickly and elimination measures
(short, medium and Iong-term) in the sense of corrective measures have to
be taken.
Term definition:
Requirements/Explanations:
For the audit, also field complaints and subsequent complaints have to be
considered accordingly. lf necessary, suitable measures have to be imple-
mented and documented following the audit criteria (see also element 15).
The results of the audit should further cause deletion from the survey of
approved suppliers/subcontractors if supplier/subcontractor fails the audit.
109
13 Service providing
DIN EN ISO 9001 Sections 4.7, 4.8, 4.9, 4.0, 4.11,
4.12, 4.13, 4.15
DIN ISO 9004-2 Sections 6.2, 6.3
110
Reference
DIN EN ISO DIN ISO
9001 9004-2
111
13.1 Upon acceptance of the order is it determined if the customer
supplies any own products and thus special measures are
required?
Term definitions:
Requirements/Explanations:
112
13.2 Have procedures and responsibilities for the order pro-
cessing been defined, covering also the required means,
methods as well as tests, and are methods for determination
of testing status defined?
Requirements/Explanations:
113
13.3 Are marking and trackability defined and traceable in each
stage of order completion?
Term definitions:
„Marking and trackability“ means that during the whole process of providing
a service it is at all times obvious which order is concerned and activities,
test results, measures and documentation can at all times be assigned to
the proper product/service.
Requirements/Explanations:
Term definitions:
114
Requirements/Explanations:
Term definitions:
115
Requirements/Explanations:
Requirements/Explanations:
116
Procedures and instructions have to be defined in writing, considering
among other things the following measures:
13.7 Are the used operating and testing means (including test
software) registered, are they regularly inspected for func-
tionality and precision, and are records thereof filed?
Requirements/Explanations:
Operating and testing means have to be suited for their application in the
continuous providing of services, functional and precise.
117
14 Customer services
(After-sales service, product observance)
DIN EN ISO 9001 Sections 4.10, 5.14, 1.19
DIN ISO 9004-2 Sections 5.1, 5.5, 6.3, 6.4
Reference
DIN EN ISO DIN ISO
9001 9004-2
118
14.1 Have procedures, processes, responsibilities and competen-
ces been defined for customer services/after sales services?
Term definition:
Requirements/Explanations:
Customer services/after sales services encompass all methods for the pro-
motion of customer contacts and become obvious for example in:
119
14.2 Are there procedures for product observance during the
stage of usage?
Requirements/Explanations:
Not only the warranty period, but the whole duration of usage should con-
sidered (e.g. also long-term evaluations).
Each manufacturer should know how his products/services will behave and
recommend themselves during the period of usage.
14.3 Are there procedures for observing the acceptance and the
effects of the provided service?
Requirements/Explanations:
Rating by the customer is the final measure for the quality of a service.
Immediate or delayed responses to occuring errors should not only be ob-
served shortly after the service has been provided, but also during the
warranty period and the whole life-time.
Each service provider has to define procedures for observing the accep-
tance and determining the proof of the results of his products/services star-
ting from delivery to the customer.
120
Corresponding information can be gathered by means of own activities such
as:
Requirements/Explanations:
The quality of a product or service must not only be audited by the producer
or service provider alone.
121
15 Analysis and improvement of services
DIN EN ISO 9001 Sections 4.14, 4.19, 4.20
DIN ISO 9004-2 Sections 6.3, 6.4
Reference
DIN EN ISO DIN ISO
9001 9004-2
122
15.1 Have procedures and competences for gathering, distributing
and analysing data and for the direction and monitoring of
measures for improving service and product quality been
defined?
Requirements/Explanations:
The responsibilities for the information system and the authorisations for
direction of improvement and monitoring have to be proven.
15.2 Are there procedures and processes for analysing error root
causes of products and services?
Requirements/Explanations:
The analysis of data from internal and external audits (including customer
responses and complaints) and quality audits has to be a purposive and
planned process. lt is the aim to identify non-fulfillment of defined quality
requirements, in particular systematic errors and their root causes, and to
derive and implement suitable error prevention measures.
123
Procedures for analysis of error causes could be e.g.:
15.3 Are there procedures and processes for analysing error root
causes of products and services?
Requirements/Explanations:
The application of statistical methods during all stages of the quality circle is
of particular importance. The method to be chosen further depends on the
products, production processes, services, kind and quantities of data as well
as the purpose of the statistical examination.
15.4 Are there statistical methods used for planning, data collec-
tion and analysis?
Term definition:
„Error prevention“ means „get it right first time“. Therefore, all processes in
the planning, implementation and usage stages have to be designed and
controlled so that errors do not occur.
Requirement/Explanations:
124
This also applies to product breakdowns and malfunctions claimed to be the
error of the personnel of the service provider or customer, for which
however the actual error cause are defectives in the service providing pro-
cess, complex processes, products and processes which are difficult to
maintain or operate or poor instruction manuals or lack of training and in-
structions.
Examples:
Requirements/Explanations:
125
Steps and activities in this program might be e.g.:
126
16 Control documents and data (definitions)
DIN EN ISO 9001 Sections 4.5, 4.16
DIN ISO 9004-2, Section 5.4
Reference
DIN EN ISO DIN ISO
9001 9004-2
127
16.1 Have responsibilities and procedures for identification,
maintenance, approval and release of quality-relevant docu-
ments and data been defined?
Term definition:
Requirements/Explanations:
Examples:
128
The above mentioned documents must be available in all involved organi-
sational units in the latest revision status. Special marking instructions given
by the customer have to be observed.
Term definition:
Requirements/Explanations:
- Distribution, availability
- Release of revisions
- Provision of latest revision (valid revision status)
- Type of highlighting revisions in the documents
- Cancellation/invalidation.
129
16.3 Is it defined where, how, and for how long quality-relevant
documents and data have to be filed?
Requirements/Explanations:
- Filing period
- Filing order
- Filing place.
Requirements/Explanations:
The service provider must have a working procedure assuring that all docu-
ments, standards, specifications, processing instructions and their revisions
received from manufacturers, suppliers and customers are duly checked,
distributed resp. introduced. This has to be recorded in a fashion similar to
the recording of own documents.
130
17 Control quality records (proofs)
DIN EN ISO 9001 Section 4.16
DIN ISO 9004-2 Sections 5.4, 6.4
Reference
DIN EN ISO DIN ISO
9001 9004-2
131
17.1 Have responsibilities and procedures for collection and review of
quality-relevant records been defined?
Term definition:
Requirements/Explanations:
132
17.2 Are there procedures and responsibilities for evaluation and
distribution of quality-relevant records?
Term definition:
Requirements/Explanations:
Requirements/Explanations:
- Filing period
- Filing order
- Filing place.
133
Filing of quality-relevant records is necessary to be able to prove at a later
data that the QM-system and the products/services have fulfilled quality
requirements at a certain date.
The filing period (archiving) and data backups have to be adapted to legal
regulations, general guidelines, customers and product liability aspects.
Requirements/Explanations:
In many cases, certain features are no longer provable at the result of the
service. So it is necessary to be able to rely on the service providers’quality
records.
134
8 Form sheets for the QM-system audit
Druckerei Henrich
D-60528 Frankfurt am Main, Schwanheimer Str. 110
(0 69) 9 67 77 - 0
(0 69) 9 67 77 - 111
135
Auftrag:
VDA QM-Systemaudit
Datum:
VDA
Qualitätsmanagement
in der Automobilindustrie
Dienstleistung
Grundlagen DIN EN ISO 9001, 9002, 9004-1 und DIN ISO 9004-2
Systemaudit-
bericht
136
QM-Systemaudit Auftrag:
VDA Gesamteinstufung Seite: 2
Firma: Auftragsgrund:
Auftraggeber: 0
Einstufungsergebnis:
Erfüllungsgrad (%) EU EP EGES
Einstufung Auditor (bei Abstufung gem. Abs. 3.4.3 Anmerkung 1 u. 2
Bemerkungen zur Einstufung (Auditor):
Systemeinstufung:
Unterschriften: Auditor/in:
Firma:
Leitung Qualitätsaudit Lieferanten
Firma:
137
QM-Systemaudit Auftrag: 0
VDA Ergebnisübersicht
Seite: 3
Ziel
Mindestforderungen
Teil U: Unternehmensführung
1 Verantwort. der Leitung
2 QM-System
3 Interne Qualitätsaudits
4 Schulung, Personal
5 Fin. Überlegungen zu QM-Syst.
6 Produktsicherheit
Z1 Unternehmensstrategie
Eu Mittelwert 1-6, Z1
138
Auftrag: 0
QM-Systemaudit
VDA Übersicht der bewerteten Fragen Seite: 4
Firma: Lief.-Nr.:
Auditfrage
139
140
QM-Systemaudit Auftrag: 0
VDA Übersicht der bewerteten Fragen Seite: 5
Firma: Lief.-Nr.:
QM-Systemaudit Prozessaudit
Qualitätsaudit Nachweisführung Beanstandung
141
9.2 Masing, Walter (Ed.)
142
9.10 DIN EN ISO 8402 (1995)
143
9.16 DIN EN ISO 9004, Part 2 (08/94)
Reference sources
144
Literature - company specific
145
10 Agreements with associations
1. A Iead auditor, approved by the VDA, has carried out a complete audit
according to VDA 6.2 (answering all applicant questions) and a fulfillment
degree of at least 90 % has been reached.
146
11.3 Procedure for applying for VDA-certificate
The complete audit report has to be attached to the application for award
the certificate.
After review at the VDA, the certificate is stamped with a registration num-
ber and signed by a Managing Director or legal representative of VDA.
147
To the
Verband der Automobilindustrie e. V. (VDA)
Lindenstraße 5
Location:
Fulfillment degree:
The completed form sheets VDA 6.2, Main selection 8, have to be attached in copy.
—————————————————————————————————————————
Lead auditor:
Company:
Co-auditor:
Company:
Complete audit
Supplement for already awarded certificate
_______________________________ ______________________________________
Place/date Signature Place/date Signature
Lead-Auditor Audited corporation
148
12 Appendix
12.1 Modifications
Comparison table sheets for comparison with DIN EN ISO 9001 are
illustrated below.
149
VDA 6.2 Subject of the item DIN EN ISO 9001
150
VDA 6.2 Subject of the item DIN EN ISO 9001
151
VDA 6.2 Subject of the item DIN EN ISO 9001
152
VDA 6.2 Subject of the item DIN EN ISO 9001
153
12.2.2 Comparison matrix DIN EN ISO 900194 /VDA 6.2
154
DIN EN Element according to DIN EN ISO 9001 VDA 6.2
ISO 9001
4.5 Control documents and data 16
.1 General remarks 16.1
.2 Approval and edition of D. & D. 16.1,16.2,16.4
.3 Modifications of documents and data 16.2
4.6 Purchasing 12
.1 General remarks 12.3
.2a Auditing subcontractors 12.1, 12.2
155
DIN EN Element according to DIN EN ISO 9001 VDA 6.2
ISO 9001
4.10 Tests 12, 13, 17
.1 General remarks 09.3, 13.2, 13.4
.2 Inspection of incoming goods 12.5
.2.1 Usage after verification 12.5
.2.2 Extent and type incoming inspection 12.5
.2.3 Preliminary or special release 12.5
.3 Interim inspection 13.4
.4 Final inspection 13.4, 17
.5 Test records 13.4, 17
4.11 Monitoring of testing means (PM) 13.7
.1 General remarks 13.7
.2a Define monitoring and testing means PM 13.7
.2b Define and calibrate testing means (PM) 13.7
.2c Define procedure for this purpose 13.7
.2d Mark calibration status 13.7
.2e Archiving calibration records 13.7
.2f Evaluation and records of previous measuring results in case 13.7
of errors of testing means (PM)
.2g Environmental conditions for measurings 13.7
.2h Handling, protection and storage of testing means (PM) 13.7
.2i Protection of calibration status 13.7
4.12 Test status 13.2
156
DIN EN Element according to DIN EN ISO 9001 VDA 6.2
ISO 9001
4.14 Corrective and preventive measures 14, 15
.1 General remarks 15.1
.2a Corrective measures, effective error elimination 14.2, 15.1
.2b K.-Correction of error causes in production, processes, 15.2
system
.2c K.-Definition of ... 15.1
.2d K.-Monitoring of effectiveness 15.1
.3 Preventive measures 15.4
4.15 Handling, storage, packaging, conservation and shipment 13
.1 General remarks 13.6
.2 Handling 13.6
.3 Storage 13.6
.4 Packaging 13.6
.5 Conservation 13.6
.6 Shipment 13.6
4.16 Control of quality records 16.3, 17
157
Other VDA-FORMS
158
Quality Management in the Automotive Industry
Volume 6 Part 1 Quality System Audit, Basics DIN EN ISO 9001 and
DIN EN ISO 9004
159