The automotive industry remains, even today, the leading sector within all branches of mechanical engineering. The development of quality management and QM systems is also inseparably linked to automotive manufacturing. While the focus in the past was primarily on internal measures to improve processes and products, today’s highly diversified industry—consisting of established car manufacturers, newcomers in the electric vehicle segment, and thousands of suppliers—requires cross-company quality management of particular importance. “Just-in-time” production and rolling inventories leave little room for issues caused by defective parts and components. Such problems would not only jeopardize revenue and profit but could also quickly develop into existential threats for companies.
Anyone in automotive manufacturing quality management who does not take the subject seriously today has little chance of winning lucrative contracts against increasingly strong competition. The industry—especially the major German car manufacturers—does not only effectively monitor itself, but also plays a key role in the further development and improvement of existing standards and norms.
Quality management in all phases of automotive construction
In the automotive sector, it has always been of particular importance that implemented quality management systems are as comprehensive and consistent as possible. It is not enough to consider only the company's own development, design and production; the focus is naturally also on the expectations and requirements of the customer for a high-end product with a high price. However, this actually trivial assumption is often still given too little attention in practice. All too often, the focus is still on the stubborn ticking off of precisely defined and measurable specifications and the passing of audits and certifications.
Fortunately, the customer is now increasingly being seen as a fixed and integral part of the value chain alongside the company itself and the existing suppliers. Today's quality management systems for the automotive industry make it possible to exploit this "extended" value chain to the full while guaranteeing the best possible quality - but you have to be able to use them accordingly.
Internal Audits in Automotive Quality Management – Independence through External Consulting and Auditors
In the automotive industry, structured internal audits are a central component of an effective quality management system. They ensure that processes are properly implemented, that regulatory and normative requirements are met, and that potential deviations are identified at an early stage. Particularly in the context of IATF 16949 and ISO 9001, internal audits are among the fundamental obligations of every certified organization.
In automotive manufacturing and among suppliers, internal audits are far more than a formal requirement. They are used to identify risks in production, development, and supply chain processes and to ensure continuous improvement within the organization. This includes, among other things:
- Process audits in production and assembly
- System audits of the quality management system
- Supplier audits along the supply chain
- Preparation for external certification or customer audits
However, an effective internal audit requires independence, technical competence, and sufficient resources. In practice, many companies encounter limitations in this regard. Quality managers must plan and execute extensive audit programs in addition to their daily operational responsibilities, while internal auditors are often drawn from the same departments they are auditing, which can make it difficult to ensure full neutrality.
When an External Auditor Makes Sense
Support from an external auditor can be useful in various situations. Companies in the automotive sector in particular rely on external expertise when:
- internal auditors are tied up with operational tasks
- an independent assessment is required
- new processes or sites need to be evaluated
- a certification or surveillance audit is approaching
- specific industry requirements (e.g. Automotive Core Tools) must be reviewed
An external auditor not only brings methodological experience from numerous audits but also provides an unbiased perspective on existing processes. This often enables faster identification of weaknesses and more targeted development of improvement measures.
Added Value of External Audits in the Automotive Sector
In automotive quality management, requirements are particularly high. OEMs and Tier 1 suppliers expect stable processes, traceable documentation, and consistent application of quality methods. An externally conducted internal audit can help to:
- systematically implement audit programs
- objectively evaluate processes along the value chain
- identify typical deviations at an early stage
- increase employee awareness of audit requirements
- prepare effectively for customer or certification audits
In addition, companies benefit from best-practice experience gained from other projects and industry environments that an experienced auditor can contribute to the assessment.
Process of an Externally Supported Internal Audit
A structured internal audit conducted with external support typically follows a clearly defined process:
- Audit planning and definition of scope
Definition of processes, sites, or departments to be audited. - Document review and preparation
Analysis of relevant QM documentation, process descriptions, and key performance indicators. - Audit execution on-site or remotely
Interviews with process owners, process walkthroughs, and sample inspections. - Evaluation and audit report
Documentation of deviations, potentials, and improvement recommendations. - Support in action planning
Derivation of concrete measures for sustainable process improvement.
Support for Automotive Companies and Suppliers
Especially small and medium-sized suppliers often benefit from having internal audits partially or fully conducted by external experts. This allows quality departments to be relieved while still ensuring professional and standards-compliant audit execution.
An external auditor not only supports individual audits but can also contribute to the development of the entire audit program—from planning and execution through to the sustainable implementation of improvement measures.
In this way, the internal audit becomes not just a mandatory task within quality management, but an effective tool for ensuring process quality and competitiveness in the automotive environment.
PeRoBa Quality Management from Munich - Individual Quality Management Automotive
Consulting, implementation, audits and QM tools from a single source
PeRoBa GmbH Munich is a service provider with many years of experience for quality management especially in automotive and mechanical engineering. We help with all important standards (VDA6.3, IATF 16949,...) on the way to certification or re-certification. We also work closely with universities and research institutes. Managing Director Dr. Scherb teaches as a lecturer, for example, at the Hamburger Fern-Hochschule, the FOM in Munich and is also a speaker at the TÜV-Süd Akademie, the Bildungswerk der Bayerischen Wirtschaft and many other institutions.
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Quality management ISO 9001, VDA 6.3 and IATF 16949 - www.peroba.org