First steps
- Contain at the supplier (controlled shipping).
- Process audit at the source.
- Escalate by scorecard class.
How to measure success
Supplier PPM and complaint count. Record the value before you start, so the effect of every action can be shown.
When these methods are the wrong choice
- Supplier scorecard: Selecting a new supplier.
- 8D report: Small internal issues where one person can fix the cause in a day.
- VDA 6.3 process audit: Quick shop-floor checks; use LPA.
- Supplier assessment: Day-to-day performance tracking; use the scorecard.
- Acceptance sampling (AQL): Improving quality; it only sorts lots.
- PPAP: Internal process problems.
The methods in one line
| Method | What it is |
|---|---|
| Supplier scorecard | Monthly rating of quality (PPM), delivery (OTD) and response, with classes A / B / C. |
| 8D report | Team-based method for customer complaints: containment, root cause for occurrence and non-detection, verified corrective action, prevention. |
| VDA 6.3 process audit | Structured process audit with scored questions and EG grading, also used at suppliers. |
| Supplier assessment | Scores a supplier’s capability by area with knock-outs, as self-assessment or on-site audit. |
| Acceptance sampling (AQL) | Lot-by-lot sampling at incoming or final inspection with defined risks. |
| PPAP | Evidence package that the supplier’s process can make good parts at rate. |