Product audit / In-process inspection / Re-certification

Article written by Milène Peter.

 

In the automotive industry, compliance with the IATF 16949:2016 standard requires a clear distinction between various assessments of product conformity and process control.

Although complementary, product audits, in-process inspections, and re-qualification serve different purposes and are neither interchangeable nor substitutable.

Product audit: independent assessment of product compliance

The product audit is required by IATF 16949 in Section 9.2.2.4.

Objectives:

• Verify that the finished product meets the specified requirements (technical, regulatory, and contractual), while taking the customer’s perspective into account (perceived quality); this also involves examining the product’s packaging and labeling;
• Identify opportunities for improvement.

When compliance cannot be directly verified on the finished product (for example, when it is assembled), the product audit may be conducted on components that have been approved at an earlier stage.

Frequency : It is defined by:

• the internal audit program,
• clients’ contractual requirements,
• or triggering events (complaints, major deviations, changes).

The results are documented in an audit report and discussed during the management review.

Although the product audit is part of the internal audit process, it is recommended that it be included in the monitoring plan.

Some customers require specific methodologies, such as VDA 6.5, through their CSRs (e.g., VW AG, Mercedes-Benz).

Example :
Quarterly audit of an electrical harness taken from the shipping inventory, including dimensional, functional, visual, and documentation checks.

 

In-process controls: operational control and monitoring

In-process inspection is part of operational control and the monitoring of manufacturing processes, in accordance with the requirements of clauses 8.5.1 (Production and Service Provision) and 9.1.1.1 (Process Monitoring and Measurement) of IATF 16949.

Objectives:

• Provide documented evidence of the product’s compliance with specified characteristics;
• Quickly detect any deviations in the production process;
• Reduce the risk of non-conforming products being delivered to the customer;
• Ensure continuous control of special characteristics, where applicable.
• Ensure traceability and the manufacturer’s legal liability;

These are performed during manufacturing, at frequencies and using methods appropriate to the criticality of the identified risks. They are derived from the process FMEA and are specified in the control plan and inspection instructions.

Example:

• SPC inspection of a critical diameter every 30 minutes;
• 100% functional testing at the end of the shift for a safety-related characteristic.

 

Recertification: periodic confirmation of compliance

Requalification is required by IATF 16949 in Section 8.6.2 (Dimensional Inspection and Functional Testing). It involves confirming, at scheduled intervals, that the product and process continue to meet the initial validation requirements (PPAP / PPA).

Objectives:

• Verify compliance with PPAP (AIAG) or PPA (VDA 2) requirements;
• Confirm the process’s long-term robustness;
• Generate contractual evidence to be included in the customer file.

Frequency:

• In accordance with customer or internal requirements,
• Always consistent with the monitoring plan.

Some manufacturers require annual re-certification (e.g., Mercedes-Benz, VW for D/TLD specifications), while others require it every three years.

Example:
A complete repeat of the initial dimensional inspections and functional tests on a production product after a 12-month production hiatus.

 

Conclusion

 

IATF 16949 requires three complementary and non-substitutable measures:

1. Product audit → Independently assess the product’s compliance from the customer’s perspective and identify opportunities for improvement.
2. In-process inspection → controlling and monitoring production in real time.
3. Requalification → periodically confirm the ongoing compliance of the product and process.

 

Clearly distinguishing between them and integrating them consistently into the automotive QMS is essential for:

• ensure regulatory and contractual compliance,
• ensure customer satisfaction,
• pass certification and second-party audits.

 

📞 Have a question? Our teams are here to listen and assist you in meeting your needs:

• France : +33 (0)2 51 13 13 00 – service.clients@euro-symbiose.fr
• Maroc / Tunisie : +212 (0)6 91 00 06 46 – service.clients@euro-symbiose.ma