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    VDA 6.3 Audit: From 68% to 92% in 8 Weeks

    January 15, 2025
    9 min read
    By Qualiteh Team

    At a Glance

    Duration8 weeks to re-audit
    Team RoleVDA 6.3 Lead Auditor & Preparation Coach
    Audit score improvement
    +24 points(from 68% to 92%)

    The Challenge

    A Tier-2 supplier of precision machined components received a VDA 6.3 process audit score of 68% during a customer assessment. With a minimum threshold of 80% required to maintain approved supplier status, they had 10 weeks to close findings and pass a re-audit or face business loss.

    The supplier had never faced formal VDA 6.3 scrutiny before. Their quality system was functional but not structured according to VDA process audit requirements. They needed both immediate gap closure and capability building for sustainable compliance.

    Specific Problems

    Below-threshold audit score
    Risk of losing approved supplier status — 68% vs 80% minimum requirement
    14 findings requiring closure
    6 major, 8 minor findings across P2-P6 — 14 findings in 8 weeks
    No VDA 6.3 experience
    Team unfamiliar with process audit methodology
    Documentation gaps
    Control plans and FMEAs not linked properly
    Limited preparation time
    Re-audit scheduled in 10 weeks, 2 weeks already passed

    Business Impact

    The consequences of failing the re-audit were significant: • Customer relationship – 5-year partnership at risk, €1.8M annual revenue • New program access – Blocked from quoting on upcoming platform • Cascading audits – Other customers likely to request similar assessments • Competitive position – Competitors positioned to take business

    The Approach

    1

    Gap Analysis and Prioritization (Week 1)

    Objective: Understand findings and create actionable closure plan

    We started with a detailed review of audit findings, mapping each to specific VDA 6.3 questions and process elements.

    Actions:
    • Reviewed audit report and categorized findings by process element (P2-P7)
    • Prioritized 6 major findings for immediate attention
    • Created RACI matrix assigning owners to each finding
    • Developed 8-week timeline with weekly milestones
    Deliverable:
    Finding closure tracker with owners, actions, and due dates
    2

    Documentation Alignment (Week 2-4)

    Objective: Align quality documentation to VDA 6.3 requirements

    Many findings stemmed from documentation that existed but was not structured or linked according to VDA expectations.

    Actions:
    • Rebuilt Control Plans with direct FMEA traceability
    • Updated PFMEAs to include detection controls referenced in audit
    • Created process flow diagrams for each audited area
    • Developed turtle diagrams for key processes
    Deliverable:
    Updated Control Plans, PFMEAs, and process documentation package
    3

    Process Implementation (Week 3-6)

    Objective: Implement missing process controls and verification

    Beyond documentation, several findings required actual process changes and new controls.

    Actions:
    • Implemented incoming inspection for critical supplier characteristics
    • Established SPC monitoring at 3 key process steps
    • Created standardized reaction plan for out-of-control conditions
    • Trained operators on updated work instructions and controls
    Deliverable:
    Implemented controls with evidence of effectiveness
    4

    Internal Audit and Coaching (Week 6-8)

    Objective: Validate readiness and prepare team for re-audit

    Before the customer re-audit, we conducted a full internal VDA 6.3 assessment and coached the team on audit interaction.

    Actions:
    • Conducted mock VDA 6.3 audit covering all P2-P7 elements
    • Identified 3 remaining gaps and closed before re-audit
    • Coached process owners on explaining their processes to auditors
    • Prepared evidence packages for each finding closure
    Deliverable:
    Internal audit report, coaching sessions, evidence binders

    The Results

    Overall audit score

    Before
    68%
    After
    92%
    +24 percentage points

    Major findings

    Before
    6
    After
    0
    100% closure

    Minor findings

    Before
    8
    After
    1
    87.5% closure

    Process element scores (P5-P6)

    Before
    58%
    After
    94%
    +36 points in production processes

    Business Impact

    • Approved supplier status maintained
    • Invited to quote on new platform program (€2.4M potential)
    • Internal team now capable of conducting VDA 6.3 self-assessments
    • Documentation structure reusable for IATF 16949 preparation

    Key Insights

    •Patterns Identified

    • •Most findings were documentation structure issues, not missing processes
    • •P5-P6 (Production) had lowest scores due to undocumented controls
    • •Team had knowledge but could not articulate it in VDA language

    Critical Success Factors

    • Early prioritization of major findings prevented last-minute scramble
    • Process owners took ownership rather than quality doing everything
    • Mock audit revealed gaps that would have been found in re-audit
    • Focus on sustainable fixes, not just audit-passing documentation
    "

    Key Takeaway

    VDA 6.3 success is not about creating perfect documentation. It is about demonstrating that you understand your processes, control your risks, and can explain both to an auditor. The documentation supports that story.

    Deliverables

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