VDA 6.3 PROCESS AUDIT REPORT

Audit Number: VDA-2026-0911
Audit Type: Process Audit (VDA 6.3:2023)
Supplier: [Redacted] Wiring Systems Co., Ltd.
Location: Changzhou, Jiangsu, China
Product: High-Voltage Wiring Harness for EV Battery Pack (Model HV-800)
Audit Date: September 8-9, 2026
Audit Duration: 2 days
Report Date: September 11, 2026
Audit Team: External Auditor (VDA certified), Supplier Quality Engineer

1. Audit Scope

This audit was conducted to evaluate the supplier's process capability for the production of high-voltage wiring harnesses used in electric vehicle battery packs. The audit covers the following processes:

• Incoming material inspection

• Cutting and stripping

• Terminal crimping

• Connector assembly

• Electrical testing

• Final inspection and packaging

• Traceability and documentation

Audit Standard: VDA 6.3:2023, Process Audit
Product Group: High-Voltage Harness, P2 (Production Process)

Audit Result: 14 non-conformities identified

• Critical: 3

• Major: 6

• Minor: 5

Overall Rating: 78% (Conditional Approval – Improvement Required)

2. Audit Findings

2.1 Non-Conformity #1 – Critical

VDA Element: P6.1.1 – Process Input (Incoming Material)

Finding:
The supplier does not verify the conformity of incoming high-voltage cable with the specified requirements. The supplier relies on the cable manufacturer's certificate of conformity without performing any incoming inspection.

Evidence:

• No incoming inspection records for high-voltage cable were available for the past 6 months.

• The supplier's incoming inspection procedure does not include high-voltage cable.

• The cable is stored in an uncontrolled area with no protection from moisture or UV light.

Requirement:
VDA 6.3 requires that incoming materials be inspected for conformity to specifications. The supplier must perform incoming inspection on high-voltage cable, including verification of:

• Conductor cross-section

• Insulation thickness

• Voltage rating

• Temperature rating

• Flexibility

Risk:
High-voltage cable that does not meet specifications can cause electrical failure, short circuit, or fire. The risk to the end customer is severe.

Corrective Action Required:
Implement incoming inspection for all high-voltage cable. Document inspection results. Store cable in a controlled environment.

Target Closure Date: October 15, 2026

2.2 Non-Conformity #2 – Critical

VDA Element: P6.2.2 – Process Control (Crimping)

Finding:
The crimping process is not fully controlled. The crimping machine settings are not documented per cable type. The operator sets the machine based on experience, not on a documented specification.

Evidence:

• No crimping parameter sheets are available at the crimping station.

• The crimping machine has no recipe management system.

• The operator was unable to provide the crimping height or width specification for the current production run.

• The crimping pull-off test is performed once per shift, not once per batch.

Requirement:
VDA 6.3 requires that critical processes be controlled with documented parameters. Crimping is a critical process for high-voltage harnesses. The crimping parameters must be specified, documented, and controlled.

Risk:
Incorrect crimping can cause high resistance, overheating, or disconnection. In a high-voltage system, this can lead to fire or electric shock.

Corrective Action Required:
Develop crimping parameter sheets for each cable type and terminal combination. Implement a recipe management system on the crimping machine. Perform pull-off testing per batch, not per shift.

Target Closure Date: October 30, 2026

2.3 Non-Conformity #3 – Critical

VDA Element: P6.4.3 – Final Inspection (Electrical Testing)

Finding:
The electrical testing process does not include a high-voltage insulation resistance test. The supplier performs continuity and low-voltage resistance testing only.

Evidence:

• The electrical test procedure does not include insulation resistance testing.

• The test fixture is not capable of performing insulation resistance testing.

• The supplier stated that insulation resistance testing is "not required by the customer."

Requirement:
For high-voltage harnesses (rated above 60V DC), insulation resistance testing is a mandatory safety requirement. The supplier must verify the insulation integrity of the completed harness.

Risk:
Insulation failure in a high-voltage harness can cause short circuit, fire, or electric shock. The risk is life-threatening.

Corrective Action Required:
Implement insulation resistance testing (500V DC, minimum 100 MΩ) for 100% of production. Procure the necessary test equipment. Update the test procedure.

Target Closure Date: November 15, 2026

2.4 Non-Conformity #4 – Major

VDA Element: P6.1.2 – Process Input (Incoming Inspection Records)

Finding:
Incoming inspection records for terminals and connectors are incomplete. The records show the inspection date and the inspector's name but do not show the measured values.

Evidence:

• Incoming inspection records show "OK" but no dimensional measurements.

• The inspection plan specifies 5 critical dimensions for the terminal. Only 1 dimension (visual) is recorded.

Risk:
Out-of-spec terminals may be accepted. This can lead to crimping defects and electrical failures.

Corrective Action Required:
Update the incoming inspection record to include all specified measurements. Train inspectors on the measurement requirements.

Target Closure Date: October 15, 2026

2.5 Non-Conformity #5 – Major

VDA Element: P6.3.1 – Personnel Qualification (Crimping Operators)

Finding:
Crimping operators are not formally qualified. The supplier has no training records or certification for crimping operators.

Evidence:

• No training records for crimping operators.

• The operator has been performing crimping for 2 years but has never been formally certified.

• No annual re-certification is performed.

Risk:
Unqualified operators may not recognize crimping defects. This can lead to defective harnesses being shipped.

Corrective Action Required:
Implement a formal crimping operator qualification program. Include written test, practical test, and annual re-certification.

Target Closure Date: November 30, 2026

2.6 Non-Conformity #6 – Major

VDA Element: P6.4.2 – Final Inspection (Test Equipment Calibration)

Finding:
The electrical test equipment is not calibrated. The calibration certificate for the test fixture expired 4 months ago.

Evidence:

• Calibration certificate expired May 2026.

• No record of calibration since.

• The test fixture is used for 100% electrical testing.

Risk:
Uncalibrated test equipment may not detect defective harnesses. Defective products may be shipped to the customer.

Corrective Action Required:
Calibrate the test fixture immediately. Implement a calibration schedule. Assign responsibility for calibration tracking.

Target Closure Date: September 30, 2026

2.7 Non-Conformity #7 – Major

VDA Element: P6.5.1 – Traceability (Batch Traceability)

Finding:
The supplier cannot trace a finished harness to the specific batch of cable, terminals, and connectors used in its production.

Evidence:

• The production record shows the production date but not the material batch numbers.

• The supplier uses a paper-based system. Records are stored in binders.

• The supplier was unable to trace a sample harness to its component batches.

Risk:
In the event of a quality issue, the supplier cannot identify the affected population. A recall would require recalling all production, not just the affected batch.

Corrective Action Required:
Implement a batch traceability system. Record material batch numbers on the production traveler. Transition to a digital system if feasible.

Target Closure Date: December 15, 2026

2.8 Non-Conformity #8 – Major

VDA Element: P6.2.3 – Process Control (Crimping Inspection)

Finding:
The crimping inspection process does not include a cross-section inspection. The supplier performs pull-off testing only.

Evidence:

• No cross-section inspection equipment is available.

• The inspection procedure does not include cross-section inspection.

• The supplier stated that cross-section inspection is "not required by the customer."

Risk:
Pull-off testing verifies strength but does not verify internal crimp quality. Cross-section inspection is required to verify wire strand compression, terminal deformation, and void presence.

Corrective Action Required:
Procure cross-section inspection equipment. Implement cross-section inspection at a defined frequency (e.g., first piece, last piece, and every 500 crimps).

Target Closure Date: November 30, 2026

2.9 Non-Conformity #9 – Major

VDA Element: P6.2.4 – Process Control (Connector Assembly)

Finding:
The connector assembly process does not include a verification of terminal insertion depth.

Evidence:

• The assembly procedure does not specify terminal insertion depth.

• No gauge or fixture is used to verify insertion depth.

• The operator verifies insertion by "feel."

Risk:
Insufficient insertion depth can cause high resistance or intermittent connection. Excessive insertion depth can damage the connector.

Corrective Action Required:
Specify terminal insertion depth. Procure a gauge or fixture to verify insertion depth. Add insertion depth verification to the assembly process.

Target Closure Date: November 15, 2026

2.10 Non-Conformity #10 – Major

VDA Element: P6.5.2 – Traceability (Documentation)

Finding:
The supplier's process documentation is incomplete. The work instructions at the crimping station are outdated (revision date: 2023).

Evidence:

• Work instruction at crimping station is revision 3, dated March 2023.

• The current process is revision 5.

• The operator is using the outdated instruction.

Risk:
The operator may not be following the current process. This can lead to inconsistent quality.

Corrective Action Required:
Update all work instructions to the current revision. Implement a document control system. Train operators on the current instructions.

Target Closure Date: October 30, 2026

2.11 Non-Conformity #11 – Minor

VDA Element: P6.1.3 – Process Input (Storage)

Finding:
Terminals and connectors are stored in open bins. The bins are not labeled with part numbers.

Risk:
Parts may be mixed. This can lead to incorrect assembly.

Corrective Action Required:
Label all bins with part numbers. Store parts in closed containers.

Target Closure Date: October 15, 2026

2.12 Non-Conformity #12 – Minor

VDA Element: P6.3.2 – Personnel Qualification (Training Records)

Finding:
Training records for assembly operators are not maintained.

Risk:
The supplier cannot demonstrate that operators are trained.

Corrective Action Required:
Maintain training records for all operators.

Target Closure Date: October 30, 2026

2.13 Non-Conformity #13 – Minor

VDA Element: P6.4.1 – Final Inspection (Inspection Records)

Finding:
Final inspection records do not include the test equipment identification number.

Risk:
The supplier cannot trace the test results to a specific test fixture.

Corrective Action Required:
Record the test equipment ID on all final inspection records.

Target Closure Date: October 15, 2026

2.14 Non-Conformity #14 – Minor

VDA Element: P6.5.3 – Traceability (Material Certificates)

Finding:
Material certificates for high-voltage cable are not maintained. The supplier could not provide certificates for the current production batch.

Risk:
The supplier cannot demonstrate that the cable meets specifications.

Corrective Action Required:
Maintain material certificates for all high-voltage cable. File certificates by batch number.

Target Closure Date: October 30, 2026

3. Summary of Non-Conformities

4. Overall Assessment

The supplier has a functional production process but lacks the process controls required for high-voltage harness manufacturing. The three critical non-conformities relate to safety-critical processes:

1. Incoming material inspection – No verification of high-voltage cable.

2. Crimping process control – No documented parameters, no recipe management.

3. Insulation resistance testing – Not performed.

These gaps must be closed before the supplier can be approved for production.

5. Corrective Action Plan

6. Follow-Up Audit

A follow-up audit is scheduled for December 15-16, 2026, to verify the closure of all non-conformities.

7. Conclusion

The supplier is not approved for production of high-voltage wiring harnesses at this time. The supplier must close the three critical non-conformities and submit evidence of closure. A follow-up audit will be conducted to verify implementation.

The supplier has acknowledged the findings and has committed to implementing the corrective actions.

8. Signatures

Lead Auditor: ______________ Date: ______________

Supplier Representative: ______________ Date: ______________

Supplier Quality Engineer: ______________ Date: ______________

This report is confidential and intended for internal use only. Distribution to third parties is prohibited without the written consent of the Quality Department.

A third-party process audit of a high-voltage harness supplier for EV battery packs. 14 non-conformities. 3 critical. Th

VDA 6.3 process audit of a high-voltage wiring harness supplier. 14 non-conformities. 3 critical. 90 days to close. Full audit report.

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